Rotary drive shaft assemblies for surgical instruments with articulatable end effectors

ABSTRACT

Drive shaft assemblies for a surgical instrument. Various forms include a plurality of movably interlocking joint segments that are interconnected to form a flexible hollow tube. A flexible secondary constraining member is configured in flexible constraining engagement with the plurality of movably interlocking joint segments to retain the interlocking joint segments in movable interlocking engagement while facilitating flexing of the drive shaft assembly.

BACKGROUND

Over the years a variety of minimally invasive robotic (or“telesurgical”) systems have been developed to increase surgicaldexterity as well as to permit a surgeon to operate on a patient in anintuitive manner. Many of such systems are disclosed in the followingU.S. Patents which are each herein incorporated by reference in theirrespective entirety: U.S. Pat. No. 5,792,135, entitled “ArticulatedSurgical Instrument For Performing Minimally Invasive Surgery WithEnhanced Dexterity and Sensitivity”, U.S. Pat. No. 6,231,565, entitled“Robotic Arm DLUS For Performing Surgical Tasks”, U.S. Pat. No.6,783,524, entitled “Robotic Surgical Tool With Ultrasound Cauterizingand Cutting Instrument”, U.S. Pat. No. 6,364,888, entitled “Alignment ofMaster and Slave In a Minimally Invasive Surgical Apparatus”, U.S. Pat.No. 7,524,320, entitled “Mechanical Actuator Interface System ForRobotic Surgical Tools”, U.S. Pat. No. 7,691,098, entitled “PlatformLink Wrist Mechanism”, U.S. Pat. No. 7,806,891, entitled “Repositioningand Reorientation of Master/Slave Relationship in Minimally InvasiveTelesurgery”, and U.S. Pat. No. 7,824,401, entitled “Surgical Tool WithWrited Monopolar Electrosurgical End Effectors”. Many of such systems,however, have in the past been unable to generate the magnitude offorces required to effectively cut and fasten tissue. In addition,existing robotic surgical systems are limited in the number of differenttypes of surgical devices that they may operate.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofexemplary embodiments of the invention taken in conjunction with theaccompanying drawings, wherein:

Various exemplary embodiments are described herein by way of example inconjunction with the following Figures wherein:

FIG. 1 is a perspective view of one robotic controller embodiment;

FIG. 2 is a perspective view of one robotic surgical armcart/manipulator of a robotic system operably supporting a plurality ofsurgical tool embodiments;

FIG. 3 is a side view of the robotic surgical arm cart/manipulatordepicted in FIG. 2;

FIG. 4 is a perspective view of a cart structure with positioninglinkages for operably supporting robotic manipulators that may be usedwith surgical tool embodiments;

FIG. 5 is a perspective view of a surgical tool embodiment and asurgical end effector embodiment;

FIG. 6 is an exploded assembly view of an adapter and tool holderarrangement for attaching various surgical tool embodiments to a roboticsystem;

FIG. 7 is a side view of the adapter shown in FIG. 6;

FIG. 8 is a bottom view of the adapter shown in FIG. 6;

FIG. 9 is a top view of the adapter of FIGS. 6 and 7;

FIG. 10 is a partial bottom perspective view of a surgical toolembodiment;

FIG. 11 is a front perspective view of a portion of a surgical toolembodiment with some elements thereof omitted for clarity;

FIG. 12 is a rear perspective view of the surgical tool embodiment ofFIG. 11;

FIG. 13 is a top view of the surgical tool embodiment of FIGS. 11 and12;

FIG. 14 is a partial top view of the surgical tool embodiment of FIGS.11-13 with the manually actuatable drive gear in an unactuated position;

FIG. 15 is another partial top view of the surgical tool embodiment ofFIGS. 11-14 with the manually actuatable drive gear in an initiallyactuated position;

FIG. 16 is another partial top view of the surgical tool embodiment ofFIGS. 11-15 with the manually actuatable drive gear in an actuatedposition;

FIG. 17 is a rear perspective view of another surgical tool embodiment;

FIG. 18 is a side elevational view of the surgical tool embodiment ofFIG. 17;

FIG. 19 is a cross-sectional view of the surgical tool embodiment ofFIG. 5 with the end effector detached from the proximal shaft portion ofthe surgical tool;

FIG. 20 is a side perspective view showing a portion of a interconnectedquick disconnect joint embodiment;

FIG. 21 is a cross-sectional view of a quick disconnect joint embodimentwith the distal shaft portion of the end effector detached from theproximal shaft portion;

FIG. 22 is another cross-sectional view of the quick disconnect jointembodiment of FIGS. 19-21 wherein the distal shaft portion has beeninitially engaged with the proximal shaft portion;

FIG. 22A is a cross-sectional view of a quick disconnect jointembodiment wherein the distal shaft portion has been initially engagedwith the proximal shaft portion;

FIG. 23 is another cross-sectional view of the quick disconnect jointembodiment of FIGS. 19-22 wherein the distal shaft portion has beenattached to the proximal shaft portion;

FIG. 23A is another cross-sectional view of the quick disconnect jointembodiment of FIG. 22A wherein the distal shaft portion has beenattached to the proximal shaft portion;

FIG. 23B is another cross-sectional view of the quick disconnect jointembodiment of FIGS. 22A, 22B wherein the distal shaft portion has beendisengaged from the proximal shaft portion;

FIG. 24 is a cross-sectional view of the distal shaft portion of FIGS.19-23 taken along line 24-24 in FIG. 21;

FIG. 25 is a cross-sectional view of a portion of an articulation jointand end effector embodiment;

FIG. 26 is an exploded assembly view of a portion of the articulationjoint and end effector of FIG. 25;

FIG. 27 is a partial cross-sectional perspective view of thearticulation joint and end effector portions depicted in FIG. 26;

FIG. 28 is a partial perspective view of an end effector and drive shaftassembly embodiment;

FIG. 29 is a partial side view of a drive shaft assembly embodiment;

FIG. 30 is a perspective view of a drive shaft assembly embodiment;

FIG. 31 is a side view of the drive shaft assembly of FIG. 31;

FIG. 32 is a perspective view of a composite drive shaft assemblyembodiment;

FIG. 33 is a side view of the composite drive shaft assembly of FIG. 33;

FIG. 34 is another view of the drive shaft assembly of FIGS. 30 and 31assuming an arcuate or “flexed” configuration;

FIG. 34A is a side view of a drive shaft assembly embodiment assuming anarcuate or “flexed” configuration;

FIG. 34B is a side view of another drive shaft assembly embodimentassuming an arcuate or “flexed” configuration;

FIG. 35 is a perspective view of a portion of another drive shaftassembly embodiment;

FIG. 36 is a top view of the drive shaft assembly embodiment of FIG. 35;

FIG. 37 is another perspective view of the drive shaft assemblyembodiment of FIGS. 35 and 36 in an arcuate configuration;

FIG. 38 is a top view of the drive shaft assembly embodiment depicted inFIG. 37;

FIG. 39 is a perspective view of another drive shaft assemblyembodiment;

FIG. 40 is another perspective view of the drive shaft assemblyembodiment of FIG. 39 in an arcuate configuration;

FIG. 41 is a top view of the drive shaft assembly embodiment of FIGS. 39and 40;

FIG. 42 is a cross-sectional view of the drive shaft assembly embodimentof FIG. 41;

FIG. 43 is a partial cross-sectional view of another drive shaftassembly embodiment;

FIG. 44 is another cross-sectional view of the drive shaft assemblyembodiment of FIG. 43;

FIG. 45 is another cross-sectional view of a portion of another driveshaft assembly embodiment;

FIG. 46 is another cross-sectional view of the drive shaft assembly ofFIG. 45;

FIG. 47 is a partial cross-sectional perspective view of an end effectorembodiment with the anvil thereof in an open position;

FIG. 48 is another partial cross-sectional perspective view of the endeffector embodiment of FIG. 47;

FIG. 49 is a side cross-sectional view of the end effector embodiment ofFIGS. 47 and 48;

FIG. 50 is another side cross-sectional view of the end effectorembodiment of FIGS. 47-49;

FIG. 51 is a partial cross-sectional perspective view of the endeffector embodiment of FIGS. 47-50 with the anvil thereof in a closedposition;

FIG. 52 is another partial cross-sectional perspective view of the endeffector embodiment of FIG. 51;

FIG. 53 is a side cross-sectional view of the end effector embodiment ofFIGS. 51 and 52 with the anvil thereof in a partially closed position;

FIG. 54 is another side cross-sectional view of the end effectorembodiment of FIGS. 51-53 with the anvil in a closed position;

FIG. 55 is a cross-sectional perspective view of another end effectorembodiment and portion of another elongate shaft assembly embodiment;

FIG. 56 is an exploded perspective view of a closure system embodiment;

FIG. 57 is a side view of the closure system embodiment of FIG. 56 withthe anvil in an open position;

FIG. 58 is a side cross-sectional view of the closure system embodimentof FIGS. 57 and 57 within an end effector embodiment wherein the anvilthereof is in an open position;

FIG. 59 is another cross-sectional view of the closure system and endeffector embodiment of FIG. 58 with the anvil thereof in a closedposition;

FIG. 59A is a front perspective view of a portion of another surgicaltool embodiment that employs the closure system embodiment of FIGS.56-59 with the actuation solenoid omitted for clarity;

FIG. 60 is an exploded assembly view of another end effector embodiment;

FIG. 61 is a partial perspective view of a drive system embodiment;

FIG. 62 is a partial front perspective view of a portion of the drivesystem embodiment of FIG. 61;

FIG. 63 is a partial rear perspective view of a portion of the drivesystem embodiment of FIGS. 61 and 62;

FIG. 64 is a partial cross-sectional side view of the drive systemembodiment of FIGS. 61-63 in a first axial drive position;

FIG. 65 is another partial cross-sectional side view of the drive systemembodiment of FIGS. 61-64 in a second axial drive position;

FIG. 66 is a cross-sectional view of an end effector and drive systemembodiment wherein the drive system is configured to fire the firingmember;

FIG. 67 is another cross-sectional view of the end effector and drivesystem embodiment wherein the drive system is configured to rotate theentire end effector;

FIG. 68 is a cross-sectional perspective view of a portion of an endeffector embodiment and articulation joint embodiment;

FIG. 69 is a cross-sectional side view of the end effector andarticulation joint embodiment depicted in FIG. 68;

FIG. 70 is a cross-sectional view of another end effector and drivesystem embodiment wherein the drive system is configured to rotate theentire end effector;

FIG. 71 is another cross-sectional view of the end effector and drivesystem embodiment of FIG. 70 wherein the drive system is configured tofire the firing member of the end effector;

FIG. 72 is a cross-sectional side view of an end effector embodiment;

FIG. 73 is an enlarged cross-sectional view of a portion of the endeffector embodiment of FIG. 72;

FIG. 74 is a cross-sectional side view of another end effectorembodiment wherein the firing member thereof has been partially driventhrough the firing stroke;

FIG. 75 is another cross-sectional side view of the end effectorembodiment of FIG. 74 wherein the firing member has been driven to theend of its firing stroke;

FIG. 76 is another cross-sectional side view of the end effectorembodiment of FIGS. 74 and 75 wherein the firing member thereof is beingretracted;

FIG. 77 is a cross-sectional side view of another end effectorembodiment wherein the firing member thereof has been partially driventhrough its firing stroke;

FIG. 78 is an exploded assembly view of a portion of an implement driveshaft embodiment;

FIG. 79 is another cross-sectional side view of the end effector of FIG.77 with the firing member thereof at the end of its firing stroke;

FIG. 80 is another cross-sectional side view of the end effector ofFIGS. 77 and 78 wherein the firing member is being retracted;

FIG. 81 is a cross-sectional side view of another end effectorembodiment wherein the firing member is at the end of its firing stroke;

FIG. 81A is an exploded assembly view of an implement drive shaft andbearing segment embodiment;

FIG. 81B is an exploded assembly view of another implement drive shaftand bearing segment embodiment;

FIG. 82 is an exploded assembly view of a firing member embodiment;

FIG. 83 is a perspective view of the firing member of FIG. 82;

FIG. 84 is a cross-sectional view of the firing member of FIGS. 82 and83 installed on a portion of an exemplary implement drive shaftembodiment;

FIG. 85 is an exploded assembly view of another firing memberembodiment;

FIG. 86 is a rear perspective view of another firing member embodiment;

FIG. 87 is a front perspective view of the firing member embodiment ofFIG. 86;

FIG. 88 is a perspective view of a firing member, implement drive shaft,wedge sled assembly and alignment portion for a surgical end effector;

FIG. 89 is a side elevational view of the firing member, implement driveshaft, wedge sled assembly and alignment portion of FIG. 88;

FIG. 90 is a cross-sectional elevational view of the surgical endeffector of FIG. 60 in a closed configuration without a staple cartridgeinstalled therein;

FIG. 91 is a bottom view of a surgical end effector having a firinglockout according to various exemplary embodiments of the presentdisclosure;

FIG. 92 is a perspective view of a portion of the bottom of the surgicalend effector of FIG. 91 in a closed and inoperable configuration;

FIG. 93 is a cross-sectional elevational view of the surgical endeffector of FIG. 91 in a closed and inoperable configuration;

FIG. 94 is an end elevational view of the surgical end effector of FIG.91 in an open and inoperable configuration;

FIG. 95 is an end elevational view of the surgical end effector of FIG.91 in a closed and inoperable configuration;

FIG. 96 is an elevational, cross-sectional view of the surgical endeffector of FIG. 91 in a closed and operable configuration having awedge sled assembly and an alignment portion in a first set of positionstherein;

FIG. 97 is another end elevational view of the surgical end effector ofFIG. 91 in a closed and operable configuration;

FIG. 98 is an exploded perspective view of a surgical end effector withsome components thereof shown in cross section and other componentsthereof omitted for clarity;

FIG. 99 is a perspective view of the biasing element depicted in FIG.98;

FIG. 100 is a perspective view of the end effector drive housingdepicted in FIG. 98;

FIG. 101 is a cross-sectional elevational view of the surgical endeffector of FIG. 98 illustrating the biasing element in a second set ofpositions;

FIG. 102 is a cross-sectional view of a portion of the surgical endeffector of FIG. 98 illustrating the implement drive shaft in aninoperable position;

FIG. 103 is a cross-sectional view of a portion of the surgical endeffector of FIG. 98 illustrating the biasing element in a first set ofpositions;

FIG. 104 is a cross-sectional view of a portion of the surgical endeffector of FIG. 98 illustrating the biasing element in a first set ofpositions and the implement drive shaft in an operable position;

FIG. 105 is a cross-sectional perspective view of an end effector for asurgical instrument comprising a drive screw configured to drive afiring member of the end effector;

FIG. 106A is a side view of a portion of a first drive screw for an endeffector comprising a first length, wherein the first drive screwincludes a single thread;

FIG. 106B is a cross-sectional end view of the first drive screw of FIG.106A;

FIG. 107A is a side view of a portion of a second drive screw for an endeffector comprising a second length, wherein the second drive screwincludes two threads;

FIG. 107B is a cross-sectional end view of the second drive screw ofFIG. 107A;

FIG. 108A is a side view of a portion of a third drive screw for an endeffector comprising a third length, wherein the third drive screwincludes three threads;

FIG. 108B is a cross-sectional end view of the third drive screw of FIG.108A;

FIG. 109A is a side view of a portion of a fourth drive screw for an endeffector comprising a fourth length, wherein the fourth drive screwincludes four threads;

FIG. 109B is a cross-sectional end view of the fourth drive screw ofFIG. 109A;

FIG. 110 is a exploded perspective view of a cutting blade for use withan end effector having a drive screw;

FIG. 111 is a perspective view of a gearing arrangement for transmittingrotation from a drive shaft to a drive screw of an end effector, whereinthe gearing arrangement is shown with portions thereof removed for thepurposes of illustration;

FIG. 112 is a perspective view of another surgical tool embodiment;

FIG. 112A is a perspective view of the end effector arrangement of thesurgical tool of FIG. 112;

FIG. 113 is an exploded assembly view of a portion of the elongate shaftassembly and quick disconnect coupler arrangement depicted in FIG. 112;

FIG. 114 is a perspective view of a portion of the elongate shaftassembly of FIGS. 112 and 113;

FIG. 115 is an enlarged exploded perspective view of the exemplary quickdisconnect coupler arrangement depicted in FIGS. 112-114;

FIG. 116 is a side elevational view of the quick disconnect couplerarrangement of FIGS. 112-115 with the locking collar thereof in anunlocked position;

FIG. 117 is another side elevational view of the quick disconnectcoupler arrangement of FIGS. 112-116 with the locking collar thereof ina locked position;

FIG. 118 is a perspective view of another surgical tool embodiment;

FIG. 119 is another perspective view of the surgical tool embodiment ofFIG. 118;

FIG. 120 is a cross-sectional perspective view of the surgical toolembodiment of FIGS. 118 and 119;

FIG. 121 is a cross-sectional perspective view of a portion of anarticulation system;

FIG. 122 is a cross-sectional view of the articulation system of FIG.121 in a neutral position;

FIG. 123 is another cross-sectional view of the articulation system ofFIGS. 121 and 122 in an articulated position;

FIG. 124 is a side elevational view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity;

FIG. 125 is a rear perspective view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity;

FIG. 126 is a rear elevational view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity;

FIG. 127 is a front perspective view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity;

FIG. 128 is a side elevational view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity;

FIG. 129 is an exploded assembly view of an exemplary reversing systemembodiment of the surgical instrument embodiment of FIGS. 118-120;

FIG. 130 is a perspective view of a lever arm embodiment of thereversing system of FIG. 129;

FIG. 131 is a perspective view of a knife retractor button of thereversing system of FIG. 129;

FIG. 132 is a perspective view of a portion of the surgical instrumentembodiment of FIGS. 118-120 with portions thereof omitted for clarityand with the lever arm in actuatable engagement with the reversing gear;

FIG. 133 is a perspective view of a portion of the surgical instrumentembodiment of FIGS. 118-120 with portions thereof omitted for clarityand with the lever arm in an unactuated position;

FIG. 134 is another perspective view of a portion of the surgicalinstrument embodiment of FIGS. 118-120 with portions thereof omitted forclarity and with the lever arm in actuatable engagement with thereversing gear;

FIG. 135 is a side elevational view of a portion of a handle assemblyportion of the surgical instrument embodiment of FIGS. 118-20 with the ashifter button assembly moved into a position which will result in therotation of the end effector when the drive shaft assembly is actuated;

FIG. 136 is another side elevational view of a portion of a handleassembly portion of the surgical instrument embodiment of FIGS. 118-120with the a shifter button assembly moved into another position whichwill result in the firing of the firing member in the end effector whenthe drive shaft assembly is actuated;

FIG. 137 is a cross-sectional view of a portion of another surgical toolembodiment with a lockable articulation joint embodiment;

FIG. 138 is another cross-sectional view of the portion of surgical toolof FIG. 137 articulated in one configuration;

FIG. 139 is another cross-sectional view of the portion of surgical toolof FIGS. 137 and 138 articulated in another configuration;

FIG. 140 is a cross-sectional of an articulation locking systemembodiment depicted in FIG. 137 taken along line 140-140 in FIG. 137;

FIG. 141 is a cross-sectional view of the articulation locking system ofFIG. 140 taken along line 141-141 in FIG. 140;

FIG. 142 is a cross-sectional view of a portion of the surgical tool ofFIG. 137 taken along line 142-142 in FIG. 137;

FIG. 143 illustrates the position of the locking wire when the first andsecond locking rings are in a clamped or locked configuration when theend effector has been articulated into a first articulation positionillustrated in FIG. 138;

FIG. 144 illustrates a position of the locking wire when the first andsecond locking rings have been sprung to their respective unclamped orunlocked positions when the end effector has been articulated to thefirst articulation position illustrated in FIG. 138;

FIG. 145 illustrates a position of the locking wire when the first andsecond locking rings are in a clamped or locked configuration when theend effector has been articulated into a second articulation positionillustrated in FIG. 139;

FIG. 146 illustrates the position of the locking wire when the first andsecond locking rings have been sprung to their respective unclamped orunlocked positions when the end effector has been articulated to thefirst articulation position illustrated in FIG. 139;

FIG. 147 is another view of the locking wire when the end effector hasbeen articulated relative to the elongate shaft assembly;

FIG. 148 is a cross-sectional view of another end effector embodimentwith the anvil assembly thereof in the closed position;

FIG. 149 is another cross-sectional view of the end effector embodimentof FIG. 148;

FIG. 150 is another cross-sectional view of the end effector embodimentof FIGS. 148 and 149 with the anvil assembly in the closed position;

FIG. 151 is another cross-sectional view of the end effector embodimentof FIGS. 148-150 illustrating the drive transmission configured to drivethe firing member;

FIG. 152 is another cross-sectional view of the end effector embodimentof FIGS. 148-151 with the drive transmission configured to rotate theentire end effector about the longitudinal tool axis;

FIG. 153 is a cross-sectional view of the end effector of FIGS. 148-152taken along line 153-153 in FIG. 148 with the drive transmissionconfigured to actuate the anvil assembly;

FIG. 154 is a cross-sectional view of the end effector of FIGS. 148-153taken along line 154-154 in FIG. 148 with the drive transmissionconfigured to fire the firing member;

FIG. 155 is a cross-sectional view of the end effector of FIGS. 148-154taken along line 155-155 in FIG. 148 with the drive transmissionconfigured to actuate the anvil assembly;

FIG. 156 is a cross-sectional view of the end effector of FIGS. 148-155taken along line 156-156 in FIG. 148;

FIG. 157 is a cross-sectional perspective view of another end effectorembodiment;

FIG. 158 is a perspective view of an elongate channel of the endeffector of FIG. 157;

FIG. 159 is a perspective view of an anvil spring embodiment;

FIG. 160 is a side cross-sectional view of the end effector of FIG. 157with the anvil in a closed position after the firing member has beendriven to its distal-most position;

FIG. 161 is a cross-sectional view of a portion of the end effector ofFIG. 160 taken along line 161-161 in FIG. 160;

FIG. 162 is another side cross-sectional view of the end effector ofFIGS. 157, 160 and 161 with the firing member being retracted;

FIG. 163 is a cross-sectional view of a portion of the end effector ofFIG. 162 taken along line 163-163;

FIG. 164 is another side cross-sectional view of the end effector ofFIGS. 157 and 160-163 with the firing member in its proximal-mostposition;

FIG. 165 is a cross-sectional view of the end effector of FIGS. 157 and160-164 taken along line 165-165 in FIG. 164;

FIG. 166 is another side cross-sectional view of the end effector ofFIGS. 157 and 160-165 after the solenoid has pulled the closure tube toits proximal-most position;

FIG. 167 is a cross-sectional view of the end effector of FIGS. 157 and160-166 taken along line 167-167 in FIG. 166;

FIG. 168 is another side cross-sectional view of the end effector ofFIGS. 157 and 160-167 with the anvil in an open position and the afterthe solenoid has pulled the closure tube to its proximal-most position;

FIG. 169 is another side cross-sectional view of the end effector ofFIGS. 157 and 160-168 after the firing member has moved to its startingposition;

FIG. 170 is another side cross-sectional view of the end effector ofFIGS. 157 and 160-169 with the anvil assembly closed and the firingmember ready to fire;

FIG. 171 is a partial cross-sectional view of another quick disconnectarrangement for coupling a distal shaft portion that may be attached toan end effector to a proximal shaft portion that may be coupled to atool mounting portion for a robotic system or to a handle assembly;

FIG. 172 is another partial cross-sectional view of the quick disconnectarrangement of FIG. 171;

FIG. 173 is an end view of the proximal shaft portion of the quickdisconnect arrangement of FIGS. 171 and 172;

FIG. 174 is cross-sectional view of an axially movable lock collarembodiment of the quick disconnect arrangement of FIGS. 171 and 172;

FIG. 174A is a perspective view of the lock collar embodiment of FIG.174;

FIG. 175 is another cross-sectional view of the quick disconnectarrangement of FIGS. 171 and 172 illustrating the initial coupling ofthe distal and proximal drive shaft portions;

FIG. 176 is another cross-sectional view of the quick disconnectarrangement of FIGS. 171, 172 and 175 illustrating the initial couplingof the corresponding articulation cable segments;

FIG. 177 is another cross-sectional view of the quick disconnectarrangement of FIG. 175 after the distal drive shaft portion has beenlocked to the proximal drive shaft portion; and

FIG. 178 is another cross-sectional view of the quick disconnectarrangement of FIG. 176 after the corresponding articulation cablesegments have been locked together.

DETAILED DESCRIPTION

Applicant of the present application also owns the following patentapplications that have been filed on even date herewith and which areeach herein incorporated by reference in their respective entireties:

1. U.S. patent application Ser. No. 13/536,271, entitled “Flexible DriveMember.”

2. U.S. patent application Ser. No. 13/536,288, entitled“Multi-Functional Powered Surgical Device with External DissectionFeatures.”

3. U.S. patent application Ser. No. 13/536,277, entitled “CouplingArrangements for Attaching Surgical End Effectors to Drive SystemsTherefor.”

4. U.S. patent application Ser. No. 13/536,295, entitled “RotaryActuatable Closure Arrangement for Surgical End Effector.”

5. U.S. patent application Ser. No. 13/536,326, entitled “Surgical EndEffectors Having Angled Tissue-Contacting Surfaces.”

6. U.S. patent application Ser. No. 13/536,303, entitled“Interchangeable End Effector Coupling Arrangement.”

7. U.S. patent application Ser. No. 13/536,393, entitled “Surgical EndEffector Jaw and Electrode Configurations.”

8. U.S. patent application Ser. No. 13/536,362, entitled “Multi-AxisArticulating and Rotating Surgical Tools.”

9. U.S. patent application Ser. No. 13/536,284, entitled “DifferentialLocking Arrangements for Rotary Powered Surgical Instruments.”

10. U.S. patent application Ser. No. 13/536,374, entitled“Interchangeable Clip Applier.”

11. U.S. patent application Ser. No. 13/536,292, entitled “Firing SystemLockout Arrangements for Surgical Instruments.”

12. U.S. patent application Ser. No. 13/536,313, entitled “Rotary DriveArrangements for Surgical Instruments.”

13. U.S. patent application Ser. No. 13/536,323, entitled “RoboticallyPowered Surgical Device With Manually-Actuatable Reversing System.”

14. U.S. patent application Ser. No. 13/536,379, entitled “ReplaceableClip Cartridge for a Clip Applier.”

15. U.S. patent application Ser. No. 13/536,386, entitled “Empty ClipCartridge Lockout.”

16. U.S. patent application Ser. No. 13/536,360, entitled “SurgicalInstrument System Including Replaceable End Effectors.”

17. U.S. patent application Ser. No. 13/536,335, entitled “RotarySupport Joint Assemblies for Coupling a First Portion of a SurgicalInstrument to a Second Portion of a Surgical Instrument.”

18. U.S. patent application Ser. No. 13/536,417, entitled “ElectrodeConnections for Rotary Driven Surgical Tools.”

Applicant also owns the following patent applications that are eachincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/118,259, entitled “SurgicalInstrument With Wireless Communication Between a Control Unit of aRobotic System and Remote Sensor”, U.S. Patent Application PublicationNo. 2011-0295270 A1;

U.S. patent application Ser. No. 13/118,210, entitled“Robotically-Controlled Disposable Motor Driven Loading Unit”, U.S.Patent Application Publication No. 2011-0290855 A1;

U.S. patent application Ser. No. 13/118,194, entitled“Robotically-Controlled Endoscopic Accessory Channel”, U.S. PatentApplication Publication No. 2011-0295242;

U.S. patent application Ser. No. 13/118,253, entitled“Robotically-Controlled Motorized Surgical Instrument”, U.S. PatentApplication Publication No. 2011-0295269 A1;

U.S. patent application Ser. No. 13/118,278, entitled“Robotically-Controlled Surgical Stapling Devices That Produce FormedStaples Having Different Lengths”, U.S. Patent Application PublicationNo. 2011-0290851 A1;

U.S. patent application Ser. No. 13/118,190, entitled“Robotically-Controlled Motorized Cutting and Fastening Instrument”,U.S. Patent Application Publication No. 2011-0288573 A1

U.S. patent application Ser. No. 13/118,223, entitled“Robotically-Controlled Shaft Based Rotary Drive Systems For SurgicalInstruments”, U.S. Patent Application Publication No. 2011-0290854 A1;

U.S. patent application Ser. No. 13/118,263, entitled“Robotically-Controlled Surgical Instrument Having RecordingCapabilities”, U.S. Patent Application Publication No. 2011-0295295 A1;

U.S. patent application Ser. No. 13/118,272, entitled“Robotically-Controlled Surgical Instrument With Force FeedbackCapabilities”, U.S. Patent Application Publication No. 2011-0290856 A1;

U.S. patent application Ser. No. 13/118,246, entitled“Robotically-Driven Surgical Instrument With E-Beam Driver”, U.S. PatentApplication Publication No. 2011-0290853 A1; and

U.S. patent application Ser. No. 13/118,241, entitled “Surgical StaplingInstruments With Rotatable Staple Deployment Arrangements”.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these exemplary embodiments are illustrated in theaccompanying drawings. Those of ordinary skill in the art willunderstand that the devices and methods specifically described hereinand illustrated in the accompanying drawings are non-limiting exemplaryembodiments and that the scope of the various exemplary embodiments ofthe present invention is defined solely by the claims. The featuresillustrated or described in connection with one exemplary embodiment maybe combined with the features of other exemplary embodiments. Suchmodifications and variations are intended to be included within thescope of the present invention.

FIG. 1 depicts a master controller 12 that is used in connection with arobotic arm slave cart 20 of the type depicted in FIG. 2. Mastercontroller 12 and robotic arm slave cart 20, as well as their respectivecomponents and control systems are collectively referred to herein as arobotic system 10. Examples of such systems and devices are disclosed inU.S. Pat. No. 7,524,320 which has been herein incorporated by reference.Thus, various details of such devices will not be described in detailherein beyond that which may be necessary to understand variousexemplary embodiments disclosed herein. As is known, the mastercontroller 12 generally includes master controllers (generallyrepresented as 14 in FIG. 1) which are grasped by the surgeon andmanipulated in space while the surgeon views the procedure via a stereodisplay 16. The master controllers 12 generally comprise manual inputdevices which preferably move with multiple degrees of freedom, andwhich often further have an actuatable handle for actuating tools (forexample, for closing grasping jaws, applying an electrical potential toan electrode, or the like).

As can be seen in FIG. 2, the robotic arm cart 20 is configured toactuate a plurality of surgical tools, generally designated as 30.Various robotic surgery systems and methods employing master controllerand robotic arm cart arrangements are disclosed in U.S. Pat. No.6,132,368, entitled “Multi-Component Telepresence System and Method”,the full disclosure of which is incorporated herein by reference. Asshown, the robotic arm cart 20 includes a base 22 from which, in theillustrated embodiment, three surgical tools 30 are supported. Thesurgical tools 30 are each supported by a series of manuallyarticulatable linkages, generally referred to as set-up joints 32, and arobotic manipulator 34. These structures are herein illustrated withprotective covers extending over much of the robotic linkage. Theseprotective covers may be optional, and may be limited in size orentirely eliminated to minimize the inertia that is encountered by theservo mechanisms used to manipulate such devices, to limit the volume ofmoving components so as to avoid collisions, and to limit the overallweight of the cart 20. The cart 20 generally has dimensions suitable fortransporting the cart 20 between operating rooms. The cart 20 isconfigured to typically fit through standard operating room doors andonto standard hospital elevators. The cart 20 would preferably have aweight and include a wheel (or other transportation) system that allowsthe cart 20 to be positioned adjacent an operating table by a singleattendant.

Referring now to FIG. 3, robotic manipulators 34 as shown include alinkage 38 that constrains movement of the surgical tool 30. Linkage 38includes rigid links coupled together by rotational joints in aparallelogram arrangement so that the surgical tool 30 rotates around apoint in space 40, as more fully described in U.S. Pat. No. 5,817,084,the full disclosure of which is herein incorporated by reference. Theparallelogram arrangement constrains rotation to pivoting about an axis40 a, sometimes called the pitch axis. The links supporting theparallelogram linkage are pivotally mounted to set-up joints 32 (FIG. 2)so that the surgical tool 30 further rotates about an axis 40 b,sometimes called the yaw axis. The pitch and yaw axes 40 a, 40 bintersect at the remote center 42, which is aligned along a shaft 44 ofthe surgical tool 30. The surgical tool 30 may have further degrees ofdriven freedom as supported by manipulator 50, including sliding motionof the surgical tool 30 along the longitudinal tool axis “LT-LT”. As thesurgical tool 30 slides along the tool axis LT-LT relative tomanipulator 50 (arrow 40 c), remote center 42 remains fixed relative tobase 52 of manipulator 50. Hence, the entire manipulator is generallymoved to re-position remote center 42. Linkage 54 of manipulator 50 isdriven by a series of motors 56. These motors actively move linkage 54in response to commands from a processor of a control system. Motors 56are also employed to manipulate the surgical tool 30. An alternativeset-up joint structure is illustrated in FIG. 4. In this embodiment, asurgical tool 30 is supported by an alternative manipulator structure50′ between two tissue manipulation tools.

Other embodiments may incorporate a wide variety of alternative roboticstructures, including those described in U.S. Pat. No. 5,878,193,entitled “Automated Endoscope System For Optimal Positioning”, the fulldisclosure of which is incorporated herein by reference. Additionally,while the data communication between a robotic component and theprocessor of the robotic surgical system is described with reference tocommunication between the surgical tool 30 and the master controller 12,similar communication may take place between circuitry of a manipulator,a set-up joint, an endoscope or other image capture device, or the like,and the processor of the robotic surgical system for componentcompatibility verification, component-type identification, componentcalibration (such as off-set or the like) communication, confirmation ofcoupling of the component to the robotic surgical system, or the like.

A surgical tool 100 that is well-adapted for use with a robotic system10 is depicted in FIG. 5. As can be seen in that Figure, the surgicaltool 100 includes a surgical end effector 1000 that comprises anendocutter. The surgical tool 100 generally includes an elongate shaftassembly 200 that is operably coupled to the manipulator 50 by a toolmounting portion, generally designated as 300. The surgical tool 100further includes an interface 302 which mechanically and electricallycouples the tool mounting portion 300 to the manipulator. One interface302 is illustrated in FIGS. 6-10. In the embodiment depicted in FIGS.6-10, the tool mounting portion 300 includes a tool mounting plate 304that operably supports a plurality of (four are shown in FIG. 10)rotatable body portions, driven discs or elements 306, that each includea pair of pins 308 that extend from a surface of the driven element 306.One pin 308 is closer to an axis of rotation of each driven elements 306than the other pin 308 on the same driven element 306, which helps toensure positive angular alignment of the driven element 306. Interface302 may include an adaptor portion 310 that is configured to mountinglyengage a mounting plate 304 as will be further discussed below. Theillustrated adaptor portion 310 includes an array of electricalconnecting pins 312 (FIG. 8) which may be coupled to a memory structureby a circuit board within the tool mounting portion 300. While interface302 is described herein with reference to mechanical, electrical, andmagnetic coupling elements, it should be understood that a wide varietyof telemetry modalities might be used, including infrared, inductivecoupling, or the like in other embodiments.

As can be seen in FIGS. 6-9, the adapter portion 310 generally includesa tool side 314 and a holder side 316. A plurality of rotatable bodies320 are mounted to a floating plate 318 which has a limited range ofmovement relative to the surrounding adaptor structure normal to themajor surfaces of the adaptor 310. Axial movement of the floating plate318 helps decouple the rotatable bodies 320 from the tool mountingportion 300 when levers or other latch formations along the sides of thetool mounting portion housing (not shown) are actuated. Otherembodiments may employ other mechanisms/arrangements for releasablycoupling the tool mounting portion 300 to the adaptor 310. In theembodiment of FIGS. 6-10, rotatable bodies 320 are resiliently mountedto floating plate 318 by resilient radial members which extend into acircumferential indentation about the rotatable bodies 320. Therotatable bodies 320 can move axially relative to plate 318 bydeflection of these resilient structures. When disposed in a first axialposition (toward tool side 314) the rotatable bodies 320 are free torotate without angular limitation. However, as the rotatable bodies 320move axially toward tool side 314, tabs 322 (extending radially from therotatable bodies 320) laterally engage detents on the floating plates soas to limit angular rotation of the rotatable bodies 320 about theiraxes. This limited rotation can be used to help drivingly engage therotatable bodies 320 with drive pins 332 of a corresponding tool holderportion 330 of the robotic system 10, as the drive pins 332 will pushthe rotatable bodies 320 into the limited rotation position until thepins 332 are aligned with (and slide into) openings 334′. Openings 334on the tool side 314 and openings 334′ on the holder side 316 ofrotatable bodies 320 are configured to accurately align the drivenelements 306 (FIG. 10) of the tool mounting portion 300 with the driveelements 336 of the tool holder 330. As described above regarding innerand outer pins 308 of driven elements 306, the openings 334, 334′ are atdiffering distances from the axis of rotation on their respectiverotatable bodies 306 so as to ensure that the alignment is not 180degrees from its intended position. Additionally, each of the openings304 may be slightly radially elongate so as to fittingly receive thepins 308 in the circumferential orientation. This allows the pins 308 toslide radially within the openings 334 and accommodate some axialmisalignment between the tool 100 and tool holder 330, while minimizingany angular misalignment and backlash between the drive and drivenelements. Openings 334 on the tool side 314 may be offset by about 90degrees from the openings 334′ (shown in broken lines) on the holderside 316, as can be seen most clearly in FIG. 9.

In the embodiment of FIGS. 6-10, an array of electrical connector pins340 are located on holder side 316 of adaptor 310 and the tool side 314of the adaptor 310 includes slots 342 (FIG. 9) for receiving a pin array(not shown) from the tool mounting portion 300. In addition totransmitting electrical signals between the surgical tool 100 and thetool holder 330, at least some of these electrical connections may becoupled to an adaptor memory device 344 (FIG. 8) by a circuit board ofthe adaptor 310.

In the embodiment of FIGS. 6-10, a detachable latch arrangement 346 isemployed to releasably affix the adaptor 310 to the tool holder 330. Asused herein, the term “tool drive assembly” when used in the context ofthe robotic system 10, at least encompasses the adapter 310 and toolholder 330 and which have been collectively generally designated as 110in FIG. 6. As can be seen in FIG. 6, the tool holder 330 includes afirst latch pin arrangement 337 that is sized to be received incorresponding clevis slots 311 provided in the adaptor 310. In addition,the tool holder 330 further has second latch pins 338 that are sized tobe retained in corresponding latch devises 313 in the adaptor 310. SeeFIG. 8. A latch assembly 315 is movably supported on the adapter 310 andhas a pair of latch devises 317 formed therein that is biasable from afirst latched position wherein the latch pins 338 are retained withintheir respective latch clevis 313 and an unlatched position wherein thedevises 317 are aligned with devises 313 to enable the second latch pins338 may be inserted into or removed from the latch devises 313. A springor springs (not shown) are employed to bias the latch assembly into thelatched position. A lip on the tool side 314 of adaptor 310 slidablyreceives laterally extending tabs of the tool mounting housing (notshown).

Referring now to FIGS. 5 and 11-16, the tool mounting portion 300operably supports a plurality of drive systems for generating variousforms of control motions necessary to operate a particular type of endeffector that is coupled to the distal end of the elongate shaftassembly 200. As shown in FIGS. 5 and 11-13, the tool mounting portion300 includes a first drive system generally designated as 350 that isconfigured to receive a corresponding “first” rotary output motion fromthe tool drive assembly 110 of the robotic system 10 and convert thatfirst rotary output motion to a first rotary control motion to beapplied to the surgical end effector. In the illustrated embodiment, thefirst rotary control motion is employed to rotate the elongate shaftassembly 200 (and surgical end effector 1000) about a longitudinal toolaxis LT-LT.

In the embodiment of FIGS. 5 and 11-13, the first drive system 350includes a tube gear segment 354 that is formed on (or attached to) theproximal end 208 of a proximal closure tube segment 202 of the elongateshaft assembly 200. The proximal end 208 of the proximal tube segment202 is rotatably supported on the tool mounting plate 304 of the toolmounting portion 300 by a forward support cradle 352 that is mounted onthe tool mounting plate 304. See FIG. 11. The tube gear segment 354 issupported in meshing engagement with a first rotational gear assembly360 that is operably supported on the tool mounting plate 304. As can beseen in FIG. 11, the rotational gear assembly 360 comprises a firstrotation drive gear 362 that is coupled to a corresponding first one ofthe driven discs or elements 306 on the holder side 316 of the toolmounting plate 304 when the tool mounting portion 300 is coupled to thetool drive assembly 110. See FIG. 10. The rotational gear assembly 360further comprises a first rotary driven gear 364 that is rotatablysupported on the tool mounting plate 304. The first rotary driven gear364 is in meshing engagement with a second rotary driven gear 366 which,in turn, is in meshing engagement with the tube gear segment 354.Application of a first rotary output motion from the tool drive assembly110 of the robotic system 10 to the corresponding driven element 306will thereby cause rotation of the rotation drive gear 362. Rotation ofthe rotation drive gear 362 ultimately results in the rotation of theelongate shaft assembly 200 (and the surgical end effector 1000) aboutthe longitudinal tool axis LT-LT (represented by arrow “R” in FIG. 5).It will be appreciated that the application of a rotary output motionfrom the tool drive assembly 110 in one direction will result in therotation of the elongate shaft assembly 200 and surgical end effector1000 about the longitudinal tool axis LT-LT in a first rotary directionand an application of the rotary output motion in an opposite directionwill result in the rotation of the elongate shaft assembly 200 andsurgical end effector 1000 in a second rotary direction that is oppositeto the first rotary direction.

In embodiment of FIGS. 5 and 11-16, the tool mounting portion 300further includes a second drive system generally designated as 370 thatis configured to receive a corresponding “second” rotary output motionfrom the tool drive assembly 110 of the robotic system 10 and convertthat second rotary output motion to a second rotary control motion forapplication to the surgical end effector. The second drive system 370includes a second rotation drive gear 372 that is coupled to acorresponding second one of the driven discs or elements 306 on theholder side 316 of the tool mounting plate 304 when the tool mountingportion 300 is coupled to the tool drive assembly 110. See FIG. 10. Thesecond drive system 370 further comprises a first rotary driven gear 374that is rotatably supported on the tool mounting plate 304. The firstrotary driven gear 374 is in meshing engagement with a shaft gear 376that is movably and non-rotatably mounted onto a proximal drive shaftsegment 380. In this illustrated embodiment, the shaft gear 376 isnon-rotatably mounted onto the proximal drive shaft segment 380 by aseries of axial keyways 384 that enable the shaft gear 376 to axiallymove on the proximal drive shaft segment 380 while being non-rotatablyaffixed thereto. Rotation of the proximal drive shaft segment 380results in the transmission of a second rotary control motion to thesurgical end effector 1000.

The second drive system 370 in the embodiment of FIGS. 5 and 11-16includes a shifting system 390 for selectively axially shifting theproximal drive shaft segment 380 which moves the shaft gear 376 into andout of meshing engagement with the first rotary driven gear 374. Forexample, as can be seen in FIGS. 11-13, the proximal drive shaft segment380 is supported within a second support cradle 382 that is attached tothe tool mounting plate 304 such that the proximal drive shaft segment380 may move axially and rotate relative to the second support cradle382. In at least one form, the shifting system 390 further includes ashifter yoke 392 that is slidably supported on the tool mounting plate304. The proximal drive shaft segment 380 is supported in the shifteryoke 392 and has a pair of collars 386 thereon such that shifting of theshifter yoke 392 on the tool mounting plate 304 results in the axialmovement of the proximal drive shaft segment 380. In at least one form,the shifting system 390 further includes a shifter solenoid 394 thatoperably interfaces with the shifter yoke 392. The shifter solenoid 394receives control power from the robotic controller 12 such that when theshifter solenoid 394 is activated, the shifter yoke 392 is moved in thedistal direction “DD”.

In this illustrated embodiment, a shaft spring 396 is journaled on theproximal drive shaft segment 380 between the shaft gear 376 and thesecond support cradle 382 to bias the shaft gear 376 in the proximaldirection “PD” and into meshing engagement with the first rotary drivengear 374. See FIGS. 11, 13 and 14. Rotation of the second rotation drivegear 372 in response to rotary output motions generated by the roboticsystem 10 ultimately results in the rotation of the proximal drive shaftsegment 380 and other drive shaft components coupled thereto (driveshaft assembly 388) about the longitudinal tool axis LT-LT. It will beappreciated that the application of a rotary output motion from the tooldrive assembly 110 in one direction will result in the rotation of theproximal drive shaft segment 380 and ultimately of the other drive shaftcomponents attached thereto in a first direction and an application ofthe rotary output motion in an opposite direction will result in therotation of the proximal drive shaft segment 380 in a second directionthat is opposite to the first direction. When it is desirable to shiftthe proximal drive shaft segment 380 in the distal direction “DD” aswill be discussed in further detail below, the robotic controller 12activates the shifter solenoid 390 to shift the shifter yoke 392 in thedistal direction “DD”.

FIGS. 17 and 18 illustrate another embodiment that employs the samecomponents of the embodiment depicted in FIGS. 5 and 11-16 except thatthis embodiment employs a battery-powered drive motor 400 for supplyingrotary drive motions to the proximal drive shaft segment 380. Sucharrangement enables the tool mounting portion to generate higher rotaryoutput motions and torque which may be advantageous when different formsof end effectors are employed. As can be seen in those Figures, themotor 400 is attached to the tool mounting plate 304 by a supportstructure 402 such that a driver gear 404 that is coupled to the motor400 is retained in meshing engagement with the shaft gear 376. In theembodiment of FIGS. 17 and 18, the support structure 402 is configuredto removably engage latch notches 303 formed in the tool mounting plate304 that are designed to facilitate attachment of a housing member (notshown) to the mounting plate 304 when the motor 400 is not employed.Thus, to employ the motor 400, the clinician removes the housing fromthe tool mounting plate 304 and then inserts the legs 403 of the supportstructure into the latch notches 303 in the tool mounting plate 304. Theproximal drive shaft segment 380 and the other drive shaft componentsattached thereto are rotated about the longitudinal tool axis LT-LT bypowering the motor 400. As illustrated, the motor 400 is batterypowered. In such arrangement, however, the motor 400 interface with therobotic controller 12 such that the robotic system 10 controls theactivation of the motor 400. In alternative embodiments, the motor 400is manually actuatable by an on/off switch (not shown) mounted on themotor 400 itself or on the tool mounting portion 300. In still otherembodiments, the motor 400 may receive power and control signals fromthe robotic system.

The embodiment illustrated in FIGS. 5 and 11-16 includes amanually-actuatable reversing system, generally designated as 410, formanually applying a reverse rotary motion to the proximal drive shaftsegment 380 in the event that the motor fails or power to the roboticsystem is lost or interrupted. Such manually-actuatable reversing system410 may also be particularly useful, for example, when the drive shaftassembly 388 becomes jammed or otherwise bound in such a way that wouldprevent reverse rotation of the drive shaft components under the motorpower alone. In the illustrated embodiment, the mechanically-actuatablereversing system 410 includes a drive gear assembly 412 that isselectively engagable with the second rotary driven gear 376 and ismanually actuatable to apply a reversing rotary motion to the proximaldrive shaft segment 380. The drive gear assembly 412 includes areversing gear 414 that is movably mounted to the tool mounting plate304. The reversing gear 414 is rotatably journaled on a pivot shaft 416that is movably mounted to the tool mounting plate 304 through a slot418. See FIG. 12. In the embodiment of FIGS. 5 and 11-16, themanually-actuatable reversing system 410 further includes a manuallyactuatable drive gear 420 that includes a body portion 422 that has anarcuate gear segment 424 formed thereon. The body portion 422 ispivotally coupled to the tool mounting plate 304 for selective pivotaltravel about an actuator axis A-A (FIG. 11) that is substantially normalto the tool mounting plate 304.

FIGS. 11-14 depict the manually-actuatable reversing system 410 in afirst unactuated position. In one exemplary form, an actuator handleportion 426 is formed on or otherwise attached to the body portion 422.The actuator handle portion 426 is sized relative to the tool mountingplate 304 such that a small amount of interference is establishedbetween the handle portion 426 and the tool mounting plate 304 to retainthe handle portion 426 in the first unactuated position. However, whenthe clinician desires to manually actuate the drive gear assembly 412,the clinician can easily overcome the interference fit by applying apivoting motion to the handle portion 426. As can also be seen in FIGS.11-14, when the drive gear assembly 412 is in the first unactuatedposition, the arcuate gear segment 424 is out of meshing engagement withthe reversing gear 414. When the clinician desires to apply a reverserotary drive motion to the proximal drive shaft segment 380, theclinician begins to apply a pivotal ratcheting motion to drive gear 420.As the drive gear 420 begins to pivot about the actuation axis A-A, aportion of the body 422 contacts a portion of the reversing gear 414 andaxially moves the reversing gear 414 in the distal direction DD takingthe drive shaft gear 376 out of meshing engagement with the first rotarydriven gear 374 of the second drive system 370. See FIG. 15. As thedrive gear 420 is pivoted, the arcuate gear segment 424 is brought intomeshing engagement with the reversing gear 414. Continued ratcheting ofthe drive gear 420 results in the application of a reverse rotary drivemotion to the drive shaft gear 376 and ultimately to the proximal driveshaft segment 380. The clinician may continue to ratchet the drive gearassembly 412 for as many times as are necessary to fully release orreverse the associated end effector component(s). Once a desired amountof reverse rotary motion has been applied to the proximal drive shaftsegment 380, the clinician returns the drive gear 420 to the starting orunactuated position wherein the arcuate gear segment 416 is out ofmeshing engagement with the drive shaft gear 376. When in that position,the shaft spring 396 once again biases the shaft gear 376 into meshingengagement with first rotary driven gear 374 of the second drive system370.

In use, the clinician may input control commands to the controller orcontrol unit of the robotic system 10 which “robotically-generates”output motions that are ultimately transferred to the various componentsof the second drive system 370. As used herein, the terms“robotically-generates” or “robotically-generated” refer to motions thatare created by powering and controlling the robotic system motors andother powered drive components. These terms are distinguishable from theterms “manually-actuatable” or “manually generated” which refer toactions taken by the clinician which result in control motions that aregenerated independent from those motions that are generated by poweringthe robotic system motors. Application of robotically-generated controlmotions to the second drive system in a first direction results in theapplication of a first rotary drive motion to the drive shaft assembly388. When the drive shaft assembly 388 is rotated in a first rotarydirection, the firing member 1200 is driven in the distal direction “DD”from its starting position toward its ending position in the endeffector 1000. Application of robotically-generated control motions tothe second drive system in a second direction results in the applicationof a second rotary drive motion to the drive shaft assembly 388. Whenthe drive shaft assembly 388 is rotated in a second rotary direction,the firing member 1200 is driven in the proximal direction “PD” from itsending position toward its starting position in the end effector 1000.When the clinician desires to manually-apply rotary control motion tothe drive shaft assembly 388, the drive shaft assembly 388 is rotated inthe second rotary direction which causes the firing member 1200 to movein the proximal direction “PD” in the end effector. Other embodimentscontaining the same components are configured such that themanual-application of a rotary control motion to the drive shaftassembly could cause the drive shaft assembly to rotate in the firstrotary direction which could be used to assist the robotically-generatedcontrol motions to drive the firing member 1200 in the distal direction.

The drive shaft assembly that is used to fire, close and rotate the endeffector can be actuated and shifted manually allowing the end effectorto release and be extracted from the surgical site as well as theabdomen even in the event that the motor(s) fail, the robotic systemloses power or other electronic failure occurs. Actuation of the handleportion 426 results in the manual generation of actuation or controlforces that are applied to the drive shaft assembly 388′ by the variouscomponents of the manually-actuatable reversing system 410. If thehandle portion 426 is in its unactuated state, it is biased out ofactuatable engagement with the reversing gear 414. The beginning of theactuation of the handle portion 426 shifts the bias. The handle 426 isconfigured for repeated actuation for as many times as are necessary tofully release the firing member 1200 and the end effector 1000.

As illustrated in FIGS. 5 and 11-16, the tool mounting portion 300includes a third drive system 430 that is configured to receive acorresponding “third” rotary output motion from the tool drive assembly110 of the robotic system 10 and convert that third rotary output motionto a third rotary control motion. The third drive system 430 includes athird drive pulley 432 that is coupled to a corresponding third one ofthe driven discs or elements 306 on the holder side 316 of the toolmounting plate 304 when the tool mounting portion 300 is coupled to thetool drive assembly 110. See FIG. 10. The third drive pulley 432 isconfigured to apply a third rotary control motion (in response tocorresponding rotary output motions applied thereto by the roboticsystem 10) to a corresponding third drive cable 434 that may be used toapply various control or manipulation motions to the end effector thatis operably coupled to the shaft assembly 200. As can be mostparticularly seen in FIGS. 11 and 12, the third drive cable 434 extendsaround a third drive spindle assembly 436. The third drive spindleassembly 436 is pivotally mounted to the tool mounting plate 304 and athird tension spring 438 is attached between the third drive spindleassembly 436 and the tool mounting plate 304 to maintain a desiredamount of tension in the third drive cable 434. As can be seen in theFigures, cable end portion 434A of the third drive cable 434 extendsaround an upper portion of a pulley block 440 that is attached to thetool mounting plate 304 and cable end portion 434B extends around asheave pulley or standoff 442 on the pulley block 440. It will beappreciated that the application of a third rotary output motion fromthe tool drive assembly 110 in one direction will result in the rotationof the third drive pulley 432 in a first direction and cause the cableend portions 434A and 434B to move in opposite directions to applycontrol motions to the end effector 1000 or elongate shaft assembly 200as will be discussed in further detail below. That is, when the thirddrive pulley 432 is rotated in a first rotary direction, the cable endportion 434A moves in a distal direction “DD” and cable end portion 434Bmoves in a proximal direction “PD”. Rotation of the third drive pulley432 in an opposite rotary direction result in the cable end portion 434Amoving in a proximal direction “PD” and cable end portion 434B moving ina distal direction “DD”.

The tool mounting portion 300 illustrated in FIGS. 5 and 11-16 includesa fourth drive system 450 that is configured to receive a corresponding“fourth” rotary output motion from the tool drive assembly 110 of therobotic system 10 and convert that fourth rotary output motion to afourth rotary control motion. The fourth drive system 450 includes afourth drive pulley 452 that is coupled to a corresponding fourth one ofthe driven discs or elements 306 on the holder side 316 of the toolmounting plate 304 when the tool mounting portion 300 is coupled to thetool drive assembly 110. See FIG. 10. The fourth drive pulley 452 isconfigured to apply a fourth rotary control motion (in response tocorresponding rotary output motions applied thereto by the roboticsystem 10) to a corresponding fourth drive cable 454 that may be used toapply various control or manipulation motions to the end effector thatis operably coupled to the shaft assembly 200. As can be mostparticularly seen in FIGS. 11 and 12, the fourth drive cable 454 extendsaround a fourth drive spindle assembly 456. The fourth drive spindleassembly 456 is pivotally mounted to the tool mounting plate 304 and afourth tension spring 458 is attached between the fourth drive spindleassembly 456 and the tool mounting plate 304 to maintain a desiredamount of tension in the fourth drive cable 454. Cable end portion 454Aof the fourth drive cable 454 extends around a bottom portion of thepulley block 440 that is attached to the tool mounting plate 304 andcable end portion 454B extends around a sheave pulley or fourth standoff462 on the pulley block 440. It will be appreciated that the applicationof a rotary output motion from the tool drive assembly 110 in onedirection will result in the rotation of the fourth drive pulley 452 ina first direction and cause the cable end portions 454A and 454B to movein opposite directions to apply control motions to the end effector orelongate shaft assembly 200 as will be discussed in further detailbelow. That is, when the fourth drive pulley 434 is rotated in a firstrotary direction, the cable end portion 454A moves in a distal direction“DD” and cable end portion 454B moves in a proximal direction “PD”.Rotation of the fourth drive pulley 452 in an opposite rotary directionresult in the cable end portion 454A moving in a proximal direction “PD”and cable end portion 454B to move in a distal direction “DD”.

The surgical tool 100 as depicted in FIG. 5 includes an articulationjoint 700. In such embodiment, the third drive system 430 may also bereferred to as a “first articulation drive system” and the fourth drivesystem 450 may be referred to herein as a “second articulation drivesystem”. Likewise, the third drive cable 434 may be referred to as a“first proximal articulation cable” and the fourth drive cable 454 maybe referred to herein as a “second proximal articulation cable”.

The tool mounting portion 300 of the embodiment illustrated in FIGS. 5and 11-16 includes a fifth drive system generally designated as 470 thatis configured to axially displace a drive rod assembly 490. The driverod assembly 490 includes a proximal drive rod segment 492 that extendsthrough the proximal drive shaft segment 380 and the drive shaftassembly 388. See FIG. 13. The fifth drive system 470 includes a movabledrive yoke 472 that is slidably supported on the tool mounting plate304. The proximal drive rod segment 492 is supported in the drive yoke372 and has a pair of retainer balls 394 thereon such that shifting ofthe drive yoke 372 on the tool mounting plate 304 results in the axialmovement of the proximal drive rod segment 492. In at least oneexemplary form, the fifth drive system 370 further includes a drivesolenoid 474 that operably interfaces with the drive yoke 472. The drivesolenoid 474 receives control power from the robotic controller 12.Actuation of the drive solenoid 474 in a first direction will cause thedrive rod assembly 490 to move in the distal direction “DD” andactuation of the drive solenoid 474 in a second direction will cause thedrive rod assembly 490 to move in the proximal direction “PD”. As can beseen in FIG. 5, the end effector 1000 includes an anvil portion that ismovable between open and closed positions upon application of axialclosure motions to a closure system. In the illustrated embodiment ofFIGS. 5 and 11-16, the fifth drive system 470 is employed to generatesuch closure motions. Thus, the fifth drive system 470 may also bereferred to as a “closure drive”.

The embodiment depicted in FIG. 5, includes a surgical end effector 1000that is attached to the tool mounting portion 300 by the elongate shaftassembly 200. In that illustrated embodiment, the elongate shaftassembly includes a coupling arrangement in the form of a quickdisconnect arrangement or joint 210 that facilitates quick attachment ofa distal portion 230 of the shaft assembly 200 to a proximal shaftportion 201 of the shaft assembly 200. The quick disconnect joint 210serves to facilitate the quick attachment and detachment of a pluralityof drive train components used to provide control motions from a sourceof drive motions to an end effector that is operably coupled thereto. Inthe embodiment illustrated in FIGS. 5 and 19, for example, the quickdisconnect joint 210 is employed to couple a distal shaft portion 230 ofend effector 1000 to a proximal shaft portion 201.

Referring now to FIGS. 19-23, the coupling arrangement or quickdisconnect joint 210 includes a proximal coupler member 212 that isconfigured to operably support proximal drive train assemblies and adistal coupler member 232 that is configured to operably support atleast one and preferably a plurality of distal drive train assemblies.In the embodiment of FIGS. 5 and 19, the third drive system 430 (i.e., afirst articulation drive system) and the fourth drive system 450 (i.e.,a second articulation drive system) are employed to apply articulationmotions to the articulation joint 700. For example, the third drivesystem 430 serves to apply control motions to the first proximalarticulation cable 434 that has cable end portions 434A, 434B toarticulate the end effector 1000 in first and second articulationdirections about the articulation joint 700. Likewise, the fourth drivesystem 450 serves to apply control motions to the second proximalarticulation cable 454 that has cable end portions 454A, 454B toarticulate the end effector 1000 in the third and fourth articulationdirections.

Referring to FIG. 20, the proximal coupler member 212 has a first pairof diametrically-opposed first slots 214 therein and a second pair ofdiametrically-opposed second slots 218 therein (only one slot 218 can beseen in FIG. 20). A first proximal articulation formation or link 222 issupported in each of the opposed first slots 214. A second proximalarticulation formation or link 226 is supported in each of the secondslots 218. The cable end portion 434A extends through a slot in one ofthe proximal articulation links 222 and is attached thereto. Likewise,the cable end portion 434B extends through a slot in the other proximalarticulation link 222 and is attached thereto. Cable end portion 434Aand its corresponding proximal articulation formation or link 222 andcable end portion 434B and its corresponding proximal articulationformation or link 222 are collectively referred to as a “first proximalarticulation drive train assembly” 217. The end cable portion 454Aextends through a slot in one of the proximal articulation links 226 andis attached thereto. The cable end portion 454B extends through a slotin the other proximal articulation link 226 and is attached thereto.Cable end portion 454A and its corresponding proximal articulationformation or link 226 and the cable end portion 454B and itscorresponding proximal articulation formation or link 226 arecollectively referred to as a “second proximal articulation drive trainassembly” 221.

As can be seen in FIG. 21, the distal shaft portion 230 includes adistal outer tube portion 231 that supports the distal coupler member232. The distal coupler member 232 has a first pair of diametricallyopposed first slots 234 therein and a second pair of diametricallyopposed second slots 238 therein. See FIG. 20. A first pair of distalarticulation formations or links 242 are supported in the opposed firstslots 234. A second pair of distal articulation formations or links 246are supported in the second pair of slots 238. A first distal cablesegment 444 extends through one of the first slots 234 and a slot in oneof the distal articulation links 242 to be attached thereto. A primarydistal cable segment 445 extends through the other one of the firstslots 234 and through a slot in the other distal articulation link 242and to be attached thereto. The first distal cable segment 444 and itscorresponding distal articulation link 242 and the primary distal cablesegment 445 and its corresponding distal articulation link 242 arecollectively referred to as a “first distal articulation drive trainassembly” 237. A second distal cable segment 446 extends through one ofthe second slots 238 and a slot in one of the distal articulation links246 and to be attached thereto. A secondary distal cable segment 447extends through the other second slot 238 and through a slot in theother distal articulation link 246 to be attached thereto. The seconddistal cable segment 446 and its corresponding distal articulation link246 and the secondary distal cable segment 447 and its correspondingdistal articulation link 246 are collectively referred to as a “seconddistal articulation drive train assembly” 241.

Each of the proximal articulation links 222 has a toothed end 224 formedon a spring arm portion 223 thereof. Each proximal articulation link 226has a toothed end 227′ formed on a spring arm portion 227. Each distalarticulation link 242 has a toothed end 243 that is configured to bemeshingly coupled with the toothed end 224 of a corresponding one of theproximal articulation links 222. Each distal articulation link 246 has atoothed end 247 that is configured to be meshingly coupled with thetoothed end 228 of a corresponding proximal articulation link 226. Whenthe proximal articulation formations or links 222, 226 are meshinglylinked with the distal articulation links 242, 246, respectively, thefirst and second proximal articulation drive train assemblies 217 and221 are operably coupled to the first and second distal articulationdrive train assemblies 237 and 241, respectively. Thus, actuation of thethird and fourth drive systems 430, 450 will apply actuation motions tothe distal cable segments 444, 445, 446, 447 as will be discussed infurther detail below.

In the embodiment of FIGS. 19-23, a distal end 250 of proximal outertube segment 202 has a series of spring fingers 252 therein that extenddistally into slots 254 configured to receive corresponding spring armportions 223, 227 therein. See FIG. 21 (spring arm portion 227 is notdepicted in FIG. 21 but can be seen in FIG. 20). Each spring finger 252has a detent 256 therein that is adapted to engage corresponding dimples258 formed in the proximal articulation links 222, 226 when the proximalarticulation links 222, 226 are in the neutral position (FIG. 23). Whenthe clinician desires to remove or attach an end effector 1000 to theproximal shaft portion 201, the third and fourth drive systems 430, 450are parked in their neutral unactuated positions.

The proximal coupler member 212 and the distal coupler member 232 of thequick disconnect joint 210 operably support corresponding portions of adrive member coupling assembly 500 for releasably coupling the proximaldrive rod segment 492 to a distal drive rod segment 520. The proximaldrive rod segment 492 comprises a proximal axial drive train assembly496 and the distal drive rod segment 520 comprises a distal axial drivetrain assembly 528. The drive member coupling assembly 500 comprises adrive rod coupler or formation 502 that comprises a receiving formationor first magnet 504 such as, for example, a rare earth magnet, etc. thatis attached to the distal end 493 of the distal drive rod segment 520.The first magnet 504 has a receiving cavity 506 formed therein forreceiving a second formation or distal magnet 510. As can be seen inFIG. 21, the distal magnet 510 is attached to a tapered mounting member512 that is attached to a proximal end 522 of the distal drive rod 520.

The proximal coupler member 212 and the distal coupler member 232 of thequick disconnect joint 210 operably support other corresponding portionsof a drive member coupling assembly 500 for releasably coupling theproximal drive shaft segment 380 with a distal drive shaft segment 540.The proximal drive shaft segment 380, in at least one exemplary form,comprises a proximal rotary drive train assembly 387 and the distaldrive shaft segment 540 comprises a distal rotary drive train assembly548. When the proximal rotary drive train assembly 387 is operablycoupled to the distal rotary drive train assembly 548, the drive shaftassembly 388 is formed to transmit rotary control motions to the endeffector 1000. In the illustrated exemplary embodiment, a proximal end542 of the distal drive shaft segment 540 has a plurality (e.g.,four—only two can be seen in FIG. 21) formations or cleated fingers 544formed thereon. Each cleated finger 544 has an attachment cleat 546formed thereon that are sized to be received in corresponding lockformations or holes or slots 383 in a distal end 381 of the proximaldrive shaft segment 380. The fingers 544 extend through a reinforcingring 545 journaled onto the proximal end 542 of the distal drive shaftsegment 540.

In the embodiment depicted in FIGS. 19-23, the drive member couplingassembly 500 further includes an unlocking tube 514 for assisting in thedisengagement of the first and second magnets 504, 510 when theclinician detaches the end effector 1000 from the proximal shaft portion201 of the surgical tool 100. The unlocking tube 514 extends through theproximal drive shaft segment 380 and its proximal end 517 protrudes outof the proximal end 385 of the proximal drive shaft segment 380 as shownin FIG. 19. The unlocking tube 514 is sized relative to the proximaldrive shaft segment 380 so as to be axially movable therein uponapplication of an unlocking motion “UL” applied to the proximal end 517thereof. A handle (not shown) is attached to the proximal end 517 of theunlocking tube to facilitate the manual application of the unlockingmotion “UL” to the unlocking tube 514 or the unlocking motion “UL”.Other embodiments that are otherwise identical to the embodiment ofFIGS. 19-23 employ an unlocking solenoid (not shown) that is attached tothe tool mounting plate 304 and powered by the robotic controller 12 ora separate battery attached thereto is employed to apply the unlockingmotion.

In the illustrated exemplary embodiment, the coupling arrangement orquick disconnect joint 210 also includes an outer lock collar 260 thatis slidably journaled on the distal end 204 of the proximal outer tubeportion 202. The outer lock collar 260 has four inwardly extendingdetents 262 that extend into a corresponding one of the slots 254 in theproximal outer tube portion 202. Use of the quick disconnect joint 210can be understood from reference to FIGS. 21-23. FIG. 21 illustrates theconditions of the proximal shaft portion 201 and the distal shaftportion 230 prior to being coupled together. As can be seen in thatFigure, the spring arm portions 223, 227 of the proximal articulationlinks 224, 226, respectively are naturally radially sprung outward. Thelocking collar 260 is moved to its proximal-most position on theproximal outer tube 202 wherein the detents 262 are at the proximal endof the slots 254 therein. When the clinician desires to attach the endeffector 1000 to the proximal shaft portion 201 of the surgical tool100, the clinician brings the distal shaft portion 230 into axialalignment and coupling engagement with the proximal shaft portion 201 asshown in FIG. 22. As can be seen in that Figure, the distal magnet 510is seated within the cavity 506 in the drive rod coupler 502 and ismagnetically attached to the proximal magnet 504 to thereby couple thedistal drive rod segment 520 to the proximal drive rod segment 492. Suchaction thereby operably couples the distal axial drive train assembly528 to the proximal axial drive train assembly 496. In addition, as theshaft portions 201, 230 are joined together, the cleated fingers 544flex inward until the cleats 546 formed thereon enter the lock openings383 in the distal end portion 381 of the proximal drive shaft segment380. When the cleats 546 are seated within their respective lockingholes 383, the distal drive shaft segment 540 is coupled to the proximaldrive shaft segment 380. Thus, such action thereby operably couples thedistal rotary drive train assembly 548 to the proximal rotary drivetrain assembly 387. As such, when distal coupler member 232 and theproximal coupler member 212 are brought into axial alignment andengagement in the manner described above and the locking collar 260 ismoved to its proximal-most position on the proximal outer tube 202, thedistal drive train assemblies are operably coupled to the proximal drivetrain assemblies.

When the clinician desires to detach the end effector 1000 from theproximal shaft portion 201 of the surgical tool 100, the clinicianreturns the third and fourth drive systems 430, 450 into their neutralpositions. The clinician may then slide the locking collar 260proximally on the proximal outer tube segment 202 into the startingposition shown in FIG. 22. When in that position, the spring armportions of the proximal articulation links 222, 226 cause the toothedportions thereof to disengage the toothed portions of the distalarticulation links 242, 246. The clinician may then apply an unlockingmotion UL to the proximal end 517 of the unlocking tube 514 to move theunlocking tube 514 and the unlocking collar 516 attached thereto in thedistal direction “DD”. As the unlocking collar 516 moves distally, itbiases the cleated fingers 544 out of engagement with their respectiveholes 383 in the distal end portion 381 of the proximal drive shaftsegment 380 and contacts the tapered mounting portion 512 to force thedistal magnet 510 out of magnetic engagement with the proximal magnet504.

FIGS. 22A, 23A and 23B depict an alternative coupling arrangement orquick disconnect joint assembly 210″ that is similar to the quickdisconnect joint 210 described above except that an electromagnet 504′is employed to couple the distal drive rod segment 520 to the proximaldrive rod segment 492′. As can be seen in these Figures, the proximaldrive rod segment 492′ is hollow to accommodate conductors 505 thatextend from a source of electrical power in the robotic system 10. Theconductors 505 are wound around a piece of iron 508. When the clinicianbrings the distal shaft portion 230 into engagement with the proximalshaft portion 201 as shown in FIG. 22A, electrical current may be passedthrough the conductors 505 in a first direction to cause the magnet 504′to attract the magnet 510 into coupling engagement as shown in FIG. 23A.When the clinician desires to detach the end effector 1000 from theproximal shaft portion 201 of the surgical tool 100, the clinicianreturns the third and fourth drive systems 430, 450 into their neutralpositions. The clinician may then slide the locking collar 260proximally on the proximal outer tube segment 202 into the startingposition shown in FIG. 22A. When in that position, the spring armportions of the proximal articulation links 222, 226 cause the toothedportions thereof to disengage the toothed portions of the distalarticulation links 242, 246. The clinician may then apply an unlockingmotion UL to the proximal end 517 of the unlocking tube 514 to move theunlocking tube 514 and the unlocking collar 516 attached thereto in thedistal direction “DD”. In addition, the electrical current may be passedthrough the conductors 505 in an opposite direction to cause theelectromagnet 504′ to repel magnet 510 to assist in separating the shaftsegments. As the clinician moves the unlocking tube distally, theunlocking collar 516 biases the cleated fingers 544 out of engagementwith their respective holes 383 in the distal end portion 381 of theproximal drive shaft segment 380 and contacts the tapered mountingportion 512 to further separate the shaft segments.

The coupling arrangements or quick detach joint assemblies describedabove may offer many advantages. For example, such arrangements mayemploy a single release/engagement motions that cannot be leftsemi-engaged. Such engagement motions can be employed to simultaneouslyoperably couple several drive train assemblies wherein at least somedrive train assemblies provide control motions that differ from thecontrol motions provided by other drive train assemblies. For example,some drive trains may provide rotary control motions and belongitudinally shiftable to provide axial control motions and some mayjust provide rotary or axial control motions. Other drive trainassemblies may provide push/pull motions for operating various endeffector systems/components. The unique and novel locking collararrangement ensures that either the distal drive train assemblies arelocked to their respective proximal drive train assemblies or they areunlocked and may be detached therefrom. When locked together, all of thedrive train assemblies are radially supported by the locking collarwhich prevents any uncoupling.

The surgical tool 100 depicted in FIGS. 5 and 11-16 includes anarticulation joint 700 that cooperates with the third and fourth drivesystems 430, 450, respectively for articulating the end effector 1000about the longitudinal tool axis “LT”. The articulation joint 700includes a proximal socket tube 702 that is attached to the distal end233 of the distal outer tube portion 231 and defines a proximal ballsocket 704 therein. See FIG. 25. A proximal ball member 706 is movablyseated within the proximal ball socket 704. As can be seen in FIG. 25,the proximal ball member 706 has a central drive passage 708 thatenables the distal drive shaft segment 540 to extend therethrough. Inaddition, the proximal ball member 706 has four articulation passages710 therein which facilitate the passage of distal cable segments 444,445, 446, 447 therethrough. As can be further seen in FIG. 25, thearticulation joint 700 further includes an intermediate articulationtube segment 712 that has an intermediate ball socket 714 formedtherein. The intermediate ball socket 714 is configured to movablysupport therein an end effector ball 722 formed on an end effectorconnector tube 720. The distal cable segments 444, 445, 446, 447 extendthrough cable passages 724 formed in the end effector ball 722 and areattached thereto by lugs 726 received within corresponding passages 728in the end effector ball 722. Other attachment arrangements may beemployed for attaching distal cable segments 444, 445, 446, 447 to theend effector ball 722.

A unique and novel rotary support joint assembly, generally designatedas 740, is depicted in FIGS. 26 and 27. The illustrated rotary supportjoint assembly 740 includes a connector portion 1012 of the end effectordrive housing 1010 that is substantially cylindrical in shape. A firstannular race 1014 is formed in the perimeter of the cylindrically-shapedconnector portion 1012. The rotary support joint assembly 740 furthercomprises a distal socket portion 730 that is formed in the end effectorconnector tube 720 as shown in FIGS. 26 and 27. The distal socketportion 730 is sized relative to the cylindrical connector portion 1012such that the connector portion 1012 can freely rotate within the socketportion 730. A second annular race 732 is formed in an inner wall 731 ofthe distal socket portion 730. A window 733 is provided through thedistal socket 730 that communicates with the second annular race 732therein. As can also be seen in FIGS. 26 and 27, the rotary supportjoint assembly 740 further includes a ring-like bearing 734. In variousexemplary embodiments, the ring-like bearing 734 comprises a plasticdeformable substantially-circular ring that has a cut 735 therein. Thecut forms free ends 736, 737 in the ring-like bearing 734. As can beseen in FIG. 26, the ring-like bearing 734 has a substantially annularshape in its natural unbiased state.

To couple a surgical end effector 1000 (e.g., a first portion of asurgical instrument) to the articulation joint 700 (e.g., a secondportion of a surgical instrument), the cylindrically shaped connectorposition 1012 is inserted into the distal socket portion 730 to bringthe second annular race 732 into substantial registry with the firstannular race 1014. One of the free ends 736, 737 of the ring-likebearing is then inserted into the registered annular races 1014, 732through the window 733 in the distal socket portion 730 of the endeffector connector tube 720. To facilitate easy insertion, the window oropening 733 has a tapered surface 738 formed thereon. See FIG. 26. Thering-like bearing 734 is essentially rotated into place and, because ittends to form a circle or ring, it does not tend to back out through thewindow 733 once installed. Once the ring-like bearing 734 has beeninserted into the registered annular races 1014, 732, the end effectorconnector tube 720 will be rotatably affixed to the connector portion1012 of the end effector drive housing 1010. Such arrangement enablesthe end effector drive housing 1010 to rotate about the longitudinaltool axis LT-LT relative to the end effector connector tube 720. Thering-like bearing 734 becomes the bearing surface that the end effectordrive housing 1010 then rotates on. Any side loading tries to deform thering-like bearing 734 which is supported and contained by the twointerlocking races 1014, 732 preventing damage to the ring-like bearing734. It will be understood that such simple and effective joint assemblyemploying the ring-like bearing 734 forms a highly lubricious interfacebetween the rotatable portions 1010, 730. If during assembly, one of thefree ends 736, 737 is permitted to protrude out through the window 733(see e.g., FIG. 27), the rotary support joint assembly 740 may bedisassembled by withdrawing the ring-like bearing member 732 out throughthe window 733. The rotary support joint assembly 740 allows for easyassembly and manufacturing while also providing for good end effectorsupport while facilitating rotary manipulation thereof.

The articulation joint 700 facilitates articulation of the end effector1000 about the longitudinal tool axis LT. For example, when it isdesirable to articulate the end effector 1000 in a first direction “FD”as shown in FIG. 5, the robotic system 10 may power the third drivesystem 430 such that the third drive spindle assembly 436 (FIGS. 11-13)is rotated in a first direction thereby drawing the proximal cable endportion 434A and ultimately distal cable segment 444 in the proximaldirection “PD” and releasing the proximal cable end portion 434B anddistal cable segment 445 to thereby cause the end effector ball 722 torotate within the socket 714. Likewise, to articulate the end effector1000 in a second direction “SD” opposite to the first direction FD, therobotic system 10 may power the third drive system 430 such that thethird drive spindle assembly 436 is rotated in a second directionthereby drawing the proximal cable end portion 434B and ultimatelydistal cable segment 445 in the proximal direction “PD” and releasingthe proximal cable end portion 434A and distal cable segment 444 tothereby cause the end effector ball 722 to rotate within the socket 714.When it is desirable to articulate the end effector 1000 in a thirddirection “TD” as shown in FIG. 5, the robotic system 10 may power thefourth drive system 450 such that the fourth drive spindle assembly 456is rotated in a third direction thereby drawing the proximal cable endportion 454A and ultimately distal cable segment 446 in the proximaldirection “PD” and releasing the proximal cable end portion 454B anddistal cable segment 447 to thereby cause the end effector ball 722 torotate within the socket 714. Likewise, to articulate the end effector1000 in a fourth direction “FTH” opposite to the third direction TD, therobotic system 10 may power the fourth drive system 450 such that thefourth drive spindle assembly 456 is rotated in a fourth directionthereby drawing the proximal cable end portion 454B and ultimatelydistal cable segment 447 in the proximal direction “PD” and releasingthe proximal cable end portion 454A and distal cable segment 446 tothereby cause the end effector ball 722 to rotate within the socket 714.

The end effector embodiment depicted in FIGS. 5 and 11-16 employs rotaryand longitudinal motions that are transmitted from the tool mountingportion 300 through the elongate shaft assembly for actuation. The driveshaft assembly employed to transmit such rotary and longitudinal motions(e.g., torsion, tension and compression motions) to the end effector isrelatively flexible to facilitate articulation of the end effector aboutthe articulation joint. FIGS. 28 and 29 illustrate an alternative driveshaft assembly 600 that may be employed in connection with theembodiment illustrated in FIGS. 5 and 11-16 or in other embodiments. Inthe embodiment depicted in FIG. 5 which employs the quick disconnectjoint 210, the proximal drive shaft segment 380 comprises a segment ofdrive shaft assembly 600 and the distal drive shaft segment 540similarly comprises another segment of drive shaft assembly 600. Thedrive shaft assembly 600 includes a drive tube 602 that has a series ofannular joint segments 604 cut therein. In that illustrated embodiment,the drive tube 602 comprises a distal portion of the proximal driveshaft segment 380.

The drive tube 602 comprises a hollow metal tube (stainless steel,titanium, etc.) that has a series of annular joint segments 604 formedtherein. The annular joint segments 604 comprise a plurality of looselyinterlocking dovetail shapes 606 that are, for example, cut into thedrive tube 602 by a laser and serve to facilitate flexible movementbetween the adjoining joint segments 604. See FIG. 29. Such lasercutting of a tube stock creates a flexible hollow drive tube that can beused in compression, tension and torsion. Such arrangement employs afull diametric cut that is interlocked with the adjacent part via a“puzzle piece” configuration. These cuts are then duplicated along thelength of the hollow drive tube in an array and are sometimes “clocked”or rotated to change the tension or torsion performance.

FIGS. 30-34 illustrate alternative exemplary micro-annular jointsegments 604′ that comprise plurality of laser cut shapes 606′ thatroughly resemble loosely interlocking, opposed “T” shapes and T-shapeswith a notched portion therein. The annular joint segments 604, 604′essentially comprise multiple micro-articulating torsion joints. Thatis, each joint segment 604, 604′ can transmit torque while facilitatingrelative articulation between each annular joint segment. As shown inFIGS. 30 and 31, the joint segment 604D′ on the distal end 603 of thedrive tube 602 has a distal mounting collar portion 608D thatfacilitates attachment to other drive components for actuating the endeffector or portions of the quick disconnect joint, etc. and the jointsegment 604P′ on the proximal end 605 of the drive tube 602 has aproximal mounting collar portion 608P′ that facilitates attachment toother proximal drive components or portions of the quick disconnectjoint.

The joint-to-joint range of motion for each particular drive shaftassembly 600 can be increased by increasing the spacing in the lasercuts. For example, to ensure that the joint segments 604′ remain coupledtogether without significantly diminishing the drive tube's ability toarticulate through desired ranges of motion, a secondary constrainingmember 610 is employed. In the embodiment depicted in FIGS. 32 and 33,the secondary constraining member 610 comprises a spring 612 or otherhelically-wound member. In various exemplary embodiments, the distal end614 of the spring 612 corresponds to the distal mounting collar portion608D and is wound tighter than the central portion 616 of the spring612. Similarly, the proximal end 618 of the spring 612 is wound tighterthan the central portion 616 of the spring 612. In other embodiments,the constraining member 610 is installed on the drive tube 602 with adesired pitch such that the constraining member also functions, forexample, as a flexible drive thread for threadably engaging otherthreaded control components on the end effector and/or the controlsystem. It will also be appreciated that the constraining member may beinstalled in such a manner as to have a variable pitch to accomplish thetransmission of the desired rotary control motions as the drive shaftassembly is rotated. For example, the variable pitch arrangement of theconstraining member may be used to enhance open/close and firing motionswhich would benefit from differing linear strokes from the same rotationmotion. In other embodiments, for example, the drive shaft assemblycomprises a variable pitch thread on a hollow flexible drive shaft thatcan be pushed and pulled around a ninety degree bend. In still otherembodiments, the secondary constraining member comprises an elastomerictube or coating 611 applied around the exterior or perimeter of thedrive tube 602 as illustrated in FIG. 34A. In still another embodiment,for example, the elastomeric tube or coating 611′ is installed in thehollow passageway 613 formed within the drive tube 602 as shown in FIG.34B.

Such drive shaft arrangements comprise a composite torsional drive axlewhich allows superior load transmission while facilitating a desirableaxial range of articulation. See, e.g., FIGS. 34 and 34A-B. That is,these composite drive shaft assemblies allow a large range of motionwhile maintaining the ability to transmit torsion in both directions aswell as facilitating the transmission of tension and compression controlmotions therethrough. In addition, the hollow nature of such drive shaftarrangements facilitate passage of other control components therethroughwhile affording improved tension loading. For example, some otherembodiments include a flexible internal cable that extends through thedrive shaft assembly which can assist in the alignment of the jointsegments while facilitating the ability to apply tension motions throughthe drive shaft assembly. Moreover, such drive shaft arrangements arerelatively easily to manufacture and assemble.

FIGS. 35-38 depict a segment 620 of a drive shaft assembly 600′. Thisembodiment includes joint segments 622, 624 that are laser cut out oftube stock material (e.g., stainless steel, titanium, polymer, etc.).The joint segments 622, 624 remain loosely attached together because thecuts 626 are radial and are somewhat tapered. For example, each of thelug portions 628 has a tapered outer perimeter portion 629 that isreceived within a socket 630 that has a tapered inner wall portion. See,e.g., FIGS. 36 and 38. Thus, there is no assembly required to attach thejoint segments 622, 624 together. As can be seen in the Figures, jointsegment 622 has opposing pivot lug portions 628 cut on each end thereofthat are pivotally received in corresponding sockets 630 formed inadjacent joint segments 624.

FIGS. 35-38 illustrate a small segment of the drive shaft assembly 600′.Those of ordinary skill in the art will appreciate that the lugs/socketsmay be cut throughout the entire length of the drive shaft assembly.That is, the joint segments 624 may have opposing sockets 630 cuttherein to facilitate linkage with adjoining joint segments 622 tocomplete the length of the drive shaft assembly 600′. In addition, thejoint segments 624 have an angled end portion 632 cut therein tofacilitate articulation of the joint segments 624 relative to the jointsegments 622 as illustrated in FIGS. 37 and 38. In the illustratedembodiment, each lug 628 has an articulation stop portion 634 that isadapted to contact a corresponding articulation stop 636 formed in thejoint segment 622. See FIGS. 37 and 38. Other embodiments, which mayotherwise be identical to the segment 620, are not provided with thearticulation stop portions 634 and stops 636.

As indicated above, the joint-to-joint range of motion for eachparticular drive shaft assembly can be increased by increasing thespacing in the laser cuts. In such embodiments, to ensure that the jointsegments 622, 624 remain coupled together without significantlydiminishing the drive tube's ability to articulate through desiredranges of motion, a secondary constraining member in the form of anelastomeric sleeve or coating 640 is employed. Other embodiments employother forms of constraining members disclosed herein and theirequivalent structures. As can be seen in FIG. 35, the joint segments622, 624 are capable of pivoting about pivot axes “PA-PA” defined by thepivot lugs 628 and corresponding sockets 630. To obtain an expandedrange of articulation, the drive shaft assembly 600′ may be rotatedabout the tool axis TL-TL while pivoting about the pivot axes PA-PA.

FIGS. 39-44 depict a segment 640 of another drive shaft assembly 600″.The drive shaft assembly 600″ comprises a multi-segment drive systemthat includes a plurality of interconnected joint segments 642 that forma flexible hollow drive tube 602″. A joint segment 642 includes a ballconnector portion 644 and a socket portion 648. Each joint segment 642may be fabricated by, for example, metal injection molding “MIM” and befabricated from 17-4, 17-7, 420 stainless steel. Other embodiments maybe machined from 300 or 400 series stainless steel, 6065 or 7071aluminum or titanium. Still other embodiments could be molded out ofplastic infilled or unfilled Nylon, Ultem, ABS, Polycarbonate orPolyethylene, for example. As can be seen in the Figures, the ballconnector 644 is hexagonal in shape. That is, the ball connector 644 hassix arcuate surfaces 646 formed thereon and is adapted to be rotatablyreceived in like-shaped sockets 650. Each socket 650 has ahexagonally-shaped outer portion 652 formed from six flat surfaces 654and a radially-shaped inner portion 656. See FIG. 42. Each joint segment642 is identical in construction, except that the socket portions of thelast joint segments forming the distal and proximal ends of the driveshaft assembly 600 may be configured to operably mate with correspondingcontrol components. Each ball connector 644 has a hollow passage 645therein that cooperate to form a hollow passageway 603 through thehollow flexible drive tube 602″.

As can be seen in FIGS. 43 and 44, the interconnected joint segments 642are contained within a constraining member 660 which comprises a tube orsleeve fabricated from a flexible polymer material, for example. FIG. 45illustrates a flexible inner core member 662 extending through theinterconnected joint segments 642. The inner core member 662 comprises asolid member fabricated from a polymer material or a hollow tube orsleeve fabricated from a flexible polymer material. FIG. 46 illustratesanother embodiment wherein a constraining member 660 and an inner coremember 662 are both employed.

Drive shaft assembly 600″ facilitates transmission of rotational andtranslational motion through a variable radius articulation joint. Thehollow nature of the drive shaft assembly 600″ provides room foradditional control components or a tensile element (e.g., a flexiblecable) to facilitate tensile and compressive load transmission. In otherembodiments, however, the joint segments 624 do not afford a hollowpassage through the drive shaft assembly. In such embodiments, forexample, the ball connector portion is solid. Rotary motion istranslated via the edges of the hexagonal surfaces. Tighter tolerancesmay allow greater load capacity. Using a cable or other tensile elementthrough the centerline of the drive shaft assembly 600″, the entiredrive shaft assembly 600″ can be rotated bent, pushed and pulled withoutlimiting range of motion. For example, the drive shaft assembly 600″ mayform an arcuate drive path, a straight drive path, a serpentine drivepath, etc.

FIGS. 5 and 47-54 illustrate one surgical end effector 1000 that may beeffectively employed with the robotic system 10. The end effector 1000comprises an endocutter 1002 that has a first jaw 1004 and a second jaw1006 that is selectively movable relative to the first jaw 1004. In theembodiment illustrated in FIGS. 5 and 47-54, the first jaw 1004comprises a support member 1019 in the form of an elongate channel 1020that is configured to operably support a staple cartridge 1030 therein.The second jaw 1006 comprises an anvil assembly 1100. As can be seen inFIGS. 47, 49, 53 and 55, the anvil assembly 1100 comprises an anvil body1102 that has a staple forming surface 1104 thereon. The anvil body 1102has a passage 1106 that is adapted to register with mounting holes 1022in the elongate channel 1020. A pivot or trunnion pin (not shown) isinserted through the holes 1022 and passage 1104 to pivotally couple theanvil 1100 to the elongate channel 1020. Such arrangement permits theanvil assembly 1100 to be selectively pivoted about a closure axis“CA-CA” that is substantially transverse to the longitudinal tool axis“LT-LT” (FIG. 48) between an open position wherein the staple formingsurface 1104 is spaced away from the cartridge deck 1044 of the staplecartridge 1040 (FIGS. 47-50) and closed positions (FIGS. 51-54) whereinthe staple forming surface 1104 on the anvil body 1102 is in confrontingrelationship relative to the cartridge deck 1042.

The embodiment of FIGS. 5 and 47-54 employs a closure assembly 1110 thatis configured to receive opening and closing motions from the fifthdrive system 470. The fifth drive system 470 serves to axially advanceand retract a drive rod assembly 490. As described above, the drive rodassembly 490 includes a proximal drive rod segment 492 that operablyinterfaces with the drive solenoid 474 to receive axial control motionstherefrom. The proximal drive rod segment 492 is coupled to a distaldrive rod segment 520 through the drive rod coupler 502. The distaldrive rod segment 520 is somewhat flexible to facilitate articulation ofthe end effector 1000 about articulation joint 700 yet facilitate theaxial transmission of closing and opening motions therethrough. Forexample, the distal drive rod segment 520 may comprise a cable orlaminate structure of titanium, stainless spring steel or Nitinol.

The closure assembly 1110 includes a closure linkage 1112 that ispivotally attached to the elongate channel 1020. As can be seen in FIGS.48, 51 and 52, the closure linkage 1112 has an opening 1114 thereinthrough which the distal end 524 of the distal drive rod segment 520extends. A ball 526 or other formation is attached to the distal driverod segment 520 to thereby attach the distal end 524 of the distal driverod segment 520 to the closure linkage 1112. The closure assembly 1110further includes a pair of cam discs 1120 that are rotatably mounted onthe lateral sides of the elongate channel 1020. One cam disc 1120 isrotatably supported on one lateral side of the elongate channel 1020 andthe other cam disc 1120 is rotatably supported to the other lateral sideof the elongate channel 1020. See FIG. 60. A pair of pivot links 1122are attached between each cam disc 1120 and the closure linkage 1112.Thus, pivotal travel of the closure linkage 1112 by the drive rodassembly 490 will result in the rotation of the cam discs 1120. Each camdisc 1120 further has an actuator pin 1124 protruding therefrom that isslidably received in a corresponding cam slot 1108 in the anvil body1102.

Actuation of the second jaw 1006 or anvil assembly 1100 will now bedescribed. FIGS. 47-50 illustrate the anvil assembly 1100 in the openposition. After the end effector 1000 has been positioned relative tothe tissue to be cut and stapled, the robotic controller 12 may activatethe drive solenoid 474 in the first or distal direction “DD” whichultimately results in the distal movement of the drive yoke 472 whichcauses the drive rod assembly 490 to move in the distal direction “DD”.Such movement of the drive rod assembly 490 results in the distalmovement of the distal drive rod segment 520 which causes the closurelinkage 1112 to pivot from the open position to the closed position(FIGS. 51-54). Such movement of the closure linkage 1112 causes the camdiscs 1120 to rotate in the “CCW” direction. As the cam discs rotate inthe “CCW” direction, interaction between the actuator pins 1124 andtheir respective cam slot 1108 causes the anvil assembly 1100 to pivotclosed onto the target tissue. To release the target tissue, the drivesolenoid 474 is activated to pull the drive rod assembly 490 in theproximal direction “PD” which results in the reverse pivotal travel ofthe closure linkage 1112 to the open position which ultimately causesthe anvil assembly 1100 to pivot back to the open position.

FIGS. 55-59 illustrate another closure system 670 for applying openingand closing motions to the anvil 1100. As can be seen in FIG. 56, forexample, the closure system 670 includes a first mounting block ormember 672 that rotatably supports a first closure rod segment 680. Thefirst closure rod segment 680 has a substantially semi-circular,cross-sectional shape. A proximal end 682 of the first closure rodsegment 680 has a first ball connector 684 thereon that is rotatablysupported within a first mounting socket 673 formed in the mountingblock 672. To facilitate articulation of the end effector 1000 by thearticulation joint 700, the first closure rod segment 680 also has afirst serrated portion 686 that coincides with the articulation joint700 as illustrated in FIGS. 58 and 59. The closure system 670 furtherincludes a second mounting block or member 674 that rotatably supports asecond closure rod segment 690. The second closure rod segment 690 has asubstantially semi-circular, cross-sectional shape. A proximal end 692of the second closure rod segment 690 has a second ball connector 694thereon that is rotatably supported within a second mounting socket 675formed in the second mounting block 674. To facilitate articulation ofthe end effector 1000 by the articulation joint 700, the second closurerod segment 690 also has a second serrated portion 696 that coincideswith the articulation joint 700 as illustrated in FIGS. 58 and 59.

As can also be seen in FIG. 56, the closure system 670 further has afirst pivot link 676 that is attached to a distal end 682 of the firstclosure rod segment 680. The first pivot link 676 has a first pivot lug677 formed thereon that is configured to be rotatably supported within afirst socket 683 formed in the distal end 682 of the first closure rodsegment 680. Such arrangement permits the first pivot link 676 to rotaterelative to the first closure rod segment 680. Likewise, a second pivotlink 678 is attached to a distal end 691 of the second closure rodsegment 690 such that it can rotate relative thereto. The second pivotlink 678 has a second pivot lug 1679 formed thereon that is configuredto extend through an opening in the first pivot lug 677 to be rotatablysupported within a second socket 692 in a distal end 1691 of the secondclosure rod segment 690. In addition, as can be seen in FIG. 56, thefirst and second pivot links 676, 678 are movably keyed to each other bya key 716 on the second pivot link 678 that is slidably received withina slot 717 in the first pivot link 676. In at least one embodiment, thefirst pivot link 676 is attached to each of the cam discs 1120 by firstlinkage arms 687 and the second pivot link 678 is attached to each ofthe cam discs 1120 by second linkage arms 688.

In the illustrated embodiment, the closure system 670 is actuated by thedrive solenoid 474. The drive solenoid 474 is configured to operablyinterface with one of the first and second mounting blocks 672, 674 toapply axial closing and opening motions thereto. As can be seen in FIGS.56-59, such drive arrangement may further comprise a first pivot linkand gear assembly 695 that is movably attached to the first mountingblock 672 by a pin 685 that extends into a slot 696 in the first pivotlink and gear assembly 695. Similarly, a second pivot link and gearassembly 697 is movably attached to the second mounting block 674 by apin 685 that extends into a slot 698 in the second pivot link and gearassembly 697. The first pivot link and gear assembly 695 has a firstbevel gear 699A rotatably mounted thereto and the second pivot link andgear assembly 697 has a second bevel gear 699B rotatably attachedthereto. Both first and second bevel gears 699A, 699B are mounted inmeshing engagement with an idler gear 689 rotatably mounted on the toolmounting plate 302. See FIG. 59A. Thus, when the first mounting block672 is advanced in the distal direction “DD” which also results in themovement of the first closure rod segment 680 and first pivot link 676in the distal direction DD, the bevel gears 689, 699A, 699B will resultin the movement of the second closure rod 690 and second pivot link 678in the proximal direction “PD”. Likewise, when the first mounting block672 is advanced in the proximal direction “PD” which also results in themovement of the first closure rod segment 680 and first pivot link 676in the proximal direction PD, the bevel gears 689, 699A, 699B willresult in the movement of the second closure rod 690 and second pivotlink 678 in the distal direction “DD”.

FIG. 58 illustrates the anvil 1100 in the open position. As can be seenin that Figure, the first closure rod 680 is slightly proximal to thesecond closure rod 690. To close the anvil, the drive solenoid 474 ispowered to axially advance the first closure rod 680 in the distaldirection “DD”. Such action causes the first pivot link 676 and firstlinkage arms 687 to rotate the cam discs 1120 in the counter-clockwise“CCW” direction as shown in FIG. 59. Such motion also results in themovement of the second closure rod 690 is the proximal direction causingthe second pivot link 678 and second linkage arms 688 to also pull thecam discs 1120 in the counter-clockwise “CCW” direction. To open theanvil, the drive solenoid 474 applies an axial control motion to thefirst mounting block 672 to return the first and second control rodsegments 680, 690 to the positions shown in FIG. 58.

The end effector embodiment 1000 illustrated in FIG. 60 includes a drivearrangement generally designated as 748 that facilitates the selectiveapplication of rotary control motions to the end effector 1000. The endeffector 1000 includes a firing member 1200 that is threadably journaledon an implement drive shaft 1300. As can be seen in FIG. 61, theimplement drive shaft 1300 has a bearing segment 1304 formed thereonthat is rotatably supported in a bearing sleeve 1011. The implementdrive shaft 1300 has an implement drive gear 1302 that operably mesheswith a rotary transmission generally designated as 750 that operablyinterfaces with the elongate channel 1020 and is operably supported by aportion of the elongate shaft assembly 200. In one exemplary form, therotary transmission 750 includes a differential interlock assembly 760.As can be seen in FIGS. 64 and 65, the differential interlock assembly760 includes a differential housing 762 that is configured toselectively rotate relative to the end effector drive housing 1010 andto rotate with the end effector housing 1010.

The distal drive shaft segment 540 is attached to a sun gear shaft 752that has a sun gear 754 attached thereto. Thus, sun gear 754 will rotatewhen the distal drive shaft segment 540 is rotated. Sun gear 754 willalso move axially with the distal drive shaft segment 540. Thedifferential interlock assembly 760 further includes a plurality ofplanet gears 764 that are rotatably attached to the differential housing762. In at least one embodiment, for example, three planet gears 764 areemployed. Each planet gear 764 is in meshing engagement with a first endeffector ring gear 1016 formed within the end effector drive housing1010. In the illustrated exemplary embodiment shown in FIG. 60, the endeffector drive housing 1010 is non-rotatably attached to the elongatechannel 1020 by a pair of opposing attachment lugs 1018 (only oneattachment lug 1018 can be seen in FIG. 60) into correspondingattachment slots 1024 (only one attachment slot 1024 can be seen in FIG.60) formed in the proximal end 1021 of the elongate channel 1020. Othermethods of non-movably attaching the end effector drive housing 1010 tothe elongate channel 1020 may be employed or the end effector drivehousing 1010 may be integrally formed with the elongate channel 1020.Thus, rotation of the end effector drive housing 1010 will result in therotation of the elongate channel 1020 of the end effector 1000.

In the embodiment depicted in FIGS. 61-65, the differential interlockassembly 760 further includes a second ring gear 766 that is formedwithin the differential housing 762 for meshing engagement with the sungear 754. The differential interlock assembly 760 also includes a thirdring gear 768 formed in the differential housing 762 that is in meshingengagement with the implement drive gear 1302. Rotation of thedifferential housing 762 within the end effector drive housing 1010 willultimately result in the rotation of the implement drive gear 1302 andthe implement drive shaft 1300 attached thereto.

When the clinician desires to rotate the end effector 1000 about thelongitudinal tool axis LT-LT distal to the articulation joint 700 toposition the end effector in a desired orientation relative to thetarget tissue, the robotic controller 12 may activate the shiftersolenoid 394 to axially move the proximal drive shaft segment 380 suchthat the sun gear 754 is moved to a “first axial” position shown inFIGS. 65, 67 and 70. As described in detail above, the distal driveshaft segment 540 is operably coupled to the proximal drive shaftsegment 380 by the quick disconnect joint 210. Thus, axial movement ofthe proximal drive shaft segment 380 may result in the axial movement ofthe distal drive shaft segment 540 and the sun gear shaft 752 and sungear 754. As was further described above, the shifting system 390controls the axial movement of the proximal drive shaft segment 380.When in the first axial position, the sun gear 754 is in meshingengagement with the planetary gears 764 and the second ring gear 766 tothereby cause the planetary gears 764 and the differential housing 762to rotate as a unit as the sun gear 754 is rotated.

Rotation of the proximal drive shaft segment 380 is controlled by thesecond drive system 370. Rotation of the proximal drive shaft segment380 results in rotation of the distal drive shaft segment 540, the sungear shaft 752 and sun gear 754. Such rotation of the differentialhousing 762 and planetary gears 764 as a unit applies a rotary motion tothe end effector drive housing 1010 of sufficient magnitude to overcomea first amount of friction F1 between the end effector drive housing1010 and the distal socket portion 730 of the intermediate articulationtube 712 to thereby cause the end effector drive housing 1010 and endeffector 1000 attached thereto to rotate about the longitudinal toolaxis “LT-LT” relative to the distal socket tube 730. Thus, when in suchposition, the end effector drive housing 1010, the differential housing762 and the planetary gears 764 all rotate together as a unit. Becausethe implement shaft 1300 is supported by the bearing sleeve 1011 in theend effector drive housing, the implement shaft 1300 also rotates withthe end effector drive housing 1010. See FIG. 61. Thus, rotation of theend effector drive housing 1010 and the end effector 1000 does notresult in relative rotation of the implement drive shaft 1300 whichwould result in displacement of the firing member 1200. In theillustrated exemplary embodiment, such rotation of the end effector 1000distal of the articulation joint 700 does not result in rotation of theentire elongate shaft assembly 200.

When it is desired to apply a rotary drive motion to the implement driveshaft 1300 for driving the firing member 1200 within the end effector1000, the sun gear 754 is axially positioned in a “second axial”position to disengage the second ring gear 766 while meshingly engagingthe planetary gears 764 as shown in FIGS. 61, 62, 64 and 66. Thus, whenit is desired to rotate the implement drive shaft 1300, the roboticcontroller 12 activates the shifter solenoid 394 to axially position thesun gear 754 into meshing engagement with the planetary gears 764. Whenin that second axial or “firing position”, the sun gear 754 onlymeshingly engages the planetary gears 764.

Rotation of the proximal drive shaft segment 380 may be controlled bythe second drive system 370. Rotation of the proximal drive shaftsegment 380 results in rotation of the distal drive shaft segment 540,the sun gear shaft 752 and sun gear 754. As the sun gear 754 is rotatedin a first firing direction, the planetary gears 764 are also rotated.As the planetary gears 764 rotate, they also cause the differentialhousing 762 to rotate. Rotation of the differential housing 762 causesthe implement shaft 1300 to rotate due to the meshing engagement of theimplement drive gear 1302 with the third ring gear 768. Because of theamount of friction F1 existing between the end effector drive housing1010 and the distal socket portion 730 of the intermediate articulationtube 712, rotation of the planetary gears 764 does not result in therotation of the end effector housing 1010 relative to the intermediatearticulation tube 712. Thus, rotation of the drive shaft assemblyresults in rotation of the implement drive shaft 1300 without rotatingthe entire end effector 1000.

Such unique and novel rotary transmission 750 comprises a single drivesystem that can selectively rotate the end effector 1000 or fire thefiring member 1200 depending upon the axial position of the rotary driveshaft. One advantage that may be afforded by such arrangement is that itsimplifies the drives that must transverse the articulation joint 700.It also translates the central drive to the base of the elongate channel1020 so that the implement drive shaft 1300 can exist under the staplecartridge 1040 to the drive the firing member 1200. The ability for anend effector to be rotatable distal to the articulation joint may vastlyimprove the ability to position the end effector relative to the targettissue.

As indicated above, when the drive shaft assembly is positioned in afirst axial position, rotation of the drive shaft assembly may result inrotation of the entire end effector 1000 distal of the articulationjoint 700. When the drive shaft assembly is positioned in a second axialposition (in one example—proximal to the first axial position), rotationof the drive shaft assembly may result in the rotation of the implementdrive shaft 1300.

The rotary transmission embodiment depicted in FIGS. 64 and 65 includesa differential locking system 780 which is configured to retain thedrive shaft assembly in the first and second axial positions. As can beseen in FIGS. 64 and 65, the differential locking system 780 comprises afirst retention formation 756 in the sun gear shaft 752 that correspondsto the first axial position of the drive shaft assembly and a secondretention formation 758 in the sun gear shaft 752 that correspond to thesecond axial position of the drive shaft assembly. In the illustratedexemplary embodiment, the first retention formation comprises a firstradial locking groove 757 in the sun gear shaft 752 and the secondretention formation 758 comprises a second radial locking groove 759formed in the sun gear shaft 752. The first and second locking grooves757, 759 cooperate with at least one spring-biased locking member 784that is adapted to retainingly engage the locking grooves 757, 759 whenthe drive shaft assembly is in the first and second axial positions,respectively. The locking members 784 have a tapered tip 786 and aremovably supported within the differential housing 762. A radial wavespring 782 may be employed to apply a biasing force to the lockingmembers 784 as shown in FIG. 63. When the drive shaft assembly isaxially moved into the first position, the locking members 784 snap intoengagement with the first radial locking groove 7576. See FIG. 65. Whenthe drive shaft assembly is axially moved into the second axialposition, the locking members 784 snap into engagement with the secondradial locking groove 759. See FIG. 64. In alternative embodiments, thefirst and second retention formations may comprise, for example, dimplesthat correspond to each of the locking members 784. Also in alternativeembodiments wherein the drive shaft assembly is axially positionable inmore than two axial positions, addition retention formations may beemployed which correspond to each of those axial positions.

FIGS. 70 and 71 illustrate an alternative differential locking system790 that is configured to ensure that the drive shaft assembly is lockedinto one of a plurality of predetermined axial positions. Thedifferential locking system 790 is configured to ensure that the driveshaft assembly is positionable in one of the first and second axialpositions and is not inadvertently positioned in another axial positionwherein the drive system is not properly operable. In the embodimentdepicted in FIGS. 70 and 71, the differential locking system 790includes a plurality of locking springs 792 that are attached to thedrive shaft assembly. Each locking spring 792 is formed with first andsecond locking valleys 794, 796 that are separated by a pointed peakportion 798. The locking springs 792 are located to cooperate with apointed locking members 763 formed on the differential housing 762.Thus, when the pointed locking members 763 are seated in the firstlocking valley 794, the drive shaft assembly is retained in the firstaxial position and when the pointed locking members 763 are seated inthe second locking valleys 796, the drive shaft assembly is retained inthe second axial position. The pointed peak portion 798 between thefirst and second locking valleys 794, 796 ensure that the drive shaftassembly is in one of the first and second axial positions and does notget stopped in an axial position between those two axial positions. Ifadditional axial positions are desired, the locking springs may beprovided with additional locking valleys that correspond to the desiredaxial positions.

Referring to FIGS. 60, 72 and 73, a thrust bearing 1030 is supportedwithin a cradle 1026 in the elongate channel 1020. The distal endportion 1306 of the implement drive shaft 1300 is rotatably receivedwithin the thrust bearing 1030 and protrudes therethrough. A retainingcollar 1032 is pinned or otherwise affixed to the distal end 1030 asshown in FIG. 73 to complete the installation. Use of the thrust bearing1030 in this manner may enable the firing member 1200 to be “pulled” asit is fired from a starting position to an ending position within theelongate channel 1020. Such arrangement may minimize the risk ofbuckling of the implement drive shaft 1300 under high load conditions.The unique and novel mounting arrangement and location of the thrustbearing 1030 may result in a seating load that increases with the anvilload which further increases the end effector stability. Such mountingarrangement may essentially serve to place the implement drive shaft1300 in tension during the high load firing cycle. This may avoid theneed for the drive system gears to both rotate the implement drive shaft1300 and resist the buckling of the shaft 1300. Use of the retainingcollar 1032 may also make the arrangement easy to manufacture andassemble. The firing member 1200 is configured to engage the anvil andretain the anvil at a desired distance from the cartridge deck as thefiring member 1200 is driven from the starting to ending position. Inthis arrangement for example, as the firing member 1200 assembly movesdistally down the elongate channel 1020, the length of the portion ofthe anvil that resembles a cantilever beam becomes shorter and stifferthereby increasing the magnitude of downward loading occurring at thedistal end of the elongate channel 1020 further increasing the bearingseating load.

One of the advantages of utilizing rotary drive members for firing,closing, rotating, etc. may include the ability to use the highmechanical advantage of the drive shaft to accommodate the high loadsneeded to accomplish those instrument tasks. However, when employingsuch rotary drive systems, it may be desirable to track the number ofrotations that the drive shaft is driven to avoid catastrophic failureor damage to the drive screw and other instrument components in theevent that the drive shaft or movable end effector component is driventoo far in the distal direction. Thus, some systems that include rotarydrive shafts have, in the past, employed encoders to track the motorrotations or sensors to monitor the axial position of the movablecomponent. The use of encoders and/or sensors require the need foradditional wiring, electronics and processing power to accommodate sucha system which can lead to increased instrument costs. Also, thesystem's reliability may be somewhat difficult to predict and itsreliability depends upon software and processors.

FIGS. 74-76 depict a mechanical stroke limiting system 1310 for limitingthe linear stroke of the firing member 1200 as the firing member 1200 isdriven from a starting to an ending position. The stroke limiting system1310 employs an implement drive shaft 1300′ wherein the screw threads1308 on the implement drive shaft 1300′ do not extend to the distal end1306 of the drive shaft 1300′. For example, as can be seen in FIGS.74-76, the implement drive shaft 1300′ includes an un-threaded section1309. The firing member 1200 has a body portion 1202 that has a seriesof internal threads 1204 that are adapted to threadably interface withthe screw threads 1308 on the implement drive shaft 1300′ such that, asthe implement drive shaft 1300′ is rotated in a first firing direction,the firing member 1200 is driven in the distal direction “DD” until itcontacts the unthreaded section 1309 at which point the firing member1200 stops its distal advancement. That is, the firing member 1200 willadvance distally until the internal threads 1204 in the firing member1200 disengage the threads 1308 in the implement drive shaft 1300′. Anyfurther rotation of the implement drive shaft 1300′ in the firstdirection will not result in further distal advancement of the firingmember 1200. See, e.g., FIG. 75.

The illustrated exemplary mechanical stroke limiting system 1310 furtherincludes a distal biasing member 1312 that is configured to be contactedby the firing member 1200 when the firing member 1200 has been advancedto the end of its distal stroke (i.e., the firing member will no longeradvance distally with the rotation of the implement drive shaft in thefirst rotary direction). In the embodiment depicted in FIGS. 74-76, forexample, the biasing member 1312 comprises a leaf spring 1314 that ispositioned within the elongate channel 1020 as shown. FIG. 74illustrates the leaf spring 1314 prior to contact by the firing member1200 and FIG. 75 illustrates the leaf spring 1314 in a compressed stateafter it has been contacted by the firing member 1200. When in thatposition, the leaf spring 1314 serves to bias the firing member 1200 inthe proximal direction “PD” to enable the internal threads 1204 in thefiring member 1200 to re-engage the implement drive shaft 1300′ when theimplement drive shaft 1300′ is rotated in a second retraction direction.As the implement drive shaft 1300′ is rotated in the second retractiondirection, the firing member 1200 is retracted in the proximaldirection. See FIG. 76.

FIGS. 77-80 illustrate another stroke limiting system 1310′. The strokelimiting system 1310′ employs a two-part implement drive shaft 1300″. Inat least one form, for example, the implement drive shaft 1300″ includesa proximal implement drive shaft segment 1320 that has a socket 1324 ina distal end 1322 thereof and a distal drive shaft segment 1330 that hasa lug 1334 protruding from a proximal end 1332 thereof. The lug 1334 issized and shaped to be received within the socket 1324 such that threads1326 on the proximal drive shaft segment 1320 cooperate with threads1336 on the distal drive shaft segment 1330 to form one continuous drivethread 1340. As can be seen in FIGS. 77, 79 and 80, a distal end 1338 ofthe distal drive shaft segment 1330 extends through a thrust bearing1032 that is movably supported in the distal end 1023 of the elongatechannel 1020. That is, the thrust bearing 1032 is axially movable withinthe elongate channel 1020. A distal biasing member 1342 is supportedwithin the elongate channel 1020 for contact with the thrust bearing1032. FIG. 78 illustrates the firing member 1200 being driven in thedistal direction “DD” as the implement drive shaft 1300″ is driven in afirst rotary direction. FIG. 79 illustrates the firing member 1200 atthe distal end of its stroke. Further rotation of the implement driveshaft 1300″ in the first rotary direction causes the thrust bearing 1032to compress the biasing member 1342 and also allows the distal shaftsegment 1330 to slip if the proximal segment 1320 continues to turn.Such slippage between the proximal and distal implement drive shaftsegments 1320, 1330 prevent the firing member 1200 from being furtheradvanced distally which could ultimately damage the instrument. However,after the first rotary motion has been discontinued, the biasing member1342 serves to bias the distal shaft segment 1320 in the proximaldirection such that the lug 1334 is seated in the socket 1324.Thereafter, rotation of the implement shaft 1300″ in a second rotarydirection results in the movement of the firing member 1200 in theproximal direction “PD” as shown in FIG. 80.

FIG. 81 illustrates another stroke limiting system 1310″. In thisembodiment, the implement drive shaft 1300 has a lug 1350 formed thereonthat is sized and shaped to be received within a socket 1352 in thebearing segment 1304 that has the implement drive gear 1302 formedthereon or otherwise attached thereto. FIGS. 81A and 81B illustratedifferent lugs 1350′ (FIG. 81A) and 1350″ (FIG. 81B) that are configuredto releasably engage corresponding sockets 1352′ and 1352″,respectively. The leaf spring 1314 is positioned to be contacted by thefiring member 1200 when the firing member 1200 has reached the end ofits stroke. Further rotation of the implement drive shaft 1300 willresult in the lug 1350, 1350′, 1350″ slipping out of the socket 1352,1352′, 1352″, respectively to thereby prevent further rotation of theimplement shaft 1300. Once the application of rotational motion to theimplement drive shaft 1300 is discontinued, the leaf spring 1314 willapply a biasing motion to the firing member 1200 to ultimately bias theimplement drive shaft 1300 in the proximal direction “PD” to seat thelug 1350 in the socket 1352. Rotation of the implement drive shaft 1300in the second rotary direction will result in the retraction of thefiring member 1200 in the proximal direction “PD” to the startingposition. Once the firing member 1200 has returned to the startingposition, the anvil 1100 may then be opened.

In the illustrated exemplary embodiment, the firing member 1200 isconfigured to engage the anvil 1100 as the firing member 1200 is drivendistally through the end effector to affirmatively space the anvil fromthe staple cartridge to assure properly formed closed staples,especially when an amount of tissue is clamped that is inadequate to doso. Other forms of firing members that are configured to engage andspace the anvil from the staple cartridge or elongate channel and whichmay be employed in this embodiment and others are disclosed in U.S. Pat.No. 6,978,921, entitled “Surgical Stapling Instrument Incorporating anE-beam Firing Mechanism”, the disclosure of which is herein incorporatedby reference in its entirety. As can be seen in FIGS. 82 and 83, thebody portion 1202 of the firing member 1200 includes a foot portion 1206that upwardly engages a channel slot 1028 in the elongate channel 1020.See FIG. 60. Similarly, the knife body includes a pair oflaterally-protruding upper fins 1208. When fired with the anvil 1100closed, the upper fins 1208 advance distally within a longitudinal anvilslot 1103 extending distally through anvil 1100. Any minor upwarddeflection in the anvil 1100 is overcome by a downward force imparted bythe upper fins 1208.

In general, the loads necessary to close and advance the firing memberi.e., “fire” the firing member could conceivably exceed 200 lbs. Suchforce requirements, however, may require the internal threads 1204 inthe firing member to comprise relative fine threads of a power-typethread configuration such as Acme threads. Further, to providesufficient support to the upper fins 1208 to avoid the firing member1200 from binding as it is driven distally through the end effector, itmay be desirable for at least 5-15 threads in the firing member to beengaged with the threads on the implement drive shaft at any given time.However, conventional manufacturing methods may be unsuitable forforming sufficient threads in the firing member body 1202 within an 0.08inch-0.150 inch diameter opening and which have sufficient thread depth.

FIGS. 82-84 illustrate a firing member 1200′ that may address at leastsome of the aforementioned challenges. As can be seen in those Figures,the body portion 1202′ of the firing member has a hollow shaft socket1210 extending therethrough that is sized to receive the implement shafttherethrough. The internal threads in this embodiment are formed by aseries of rods 1214 that extend transversely through holes 1212 in theshaft socket 1210 as shown. As can be seen in FIG. 84, the pins 1214rest on the minor diameter of the pitch of the threads 1308 on theimplement drive shaft 1300.

FIG. 85 illustrates another firing member 1200″ that may also address atleast some of the above-discussed manufacturing challenges. As can beseen in that Figure, the body portion 1202″ of the firing member 100″has a hollow shaft socket 1210 extending therethrough that is sized toreceive the implement shaft therethrough. A pair of windows 1216 areformed in the body portion 1202″ as shown. The internal threads 1220 inthis embodiment are formed on plugs 1218 that are inserted into thewindows 1216 and are attached therein by welding, adhesive, etc. FIGS.86 and 87 illustrate another firing member 1200″ wherein access into thesocket 1210 is gained through access windows 1230A, 1230B formed in thebody portion 1202″. For example, a pair of access windows 1230A areprovided through one side of the socket portion 1210 to enable internalthread segments 1232 to be formed within the opposite wall of the socket1210. Another access window 1230B is provided through the opposite sideof the socket portion 1210 so that a central internal thread segment1234 can be formed in the opposite wall between the internal threadsegments 1232. The thread segments 1232, 1234 cooperate to threadablyengage the threads 1308 on the implement drive shaft 1300.

End effector 1000 is configured to removably support a staple cartridge1040 therein. See FIG. 60. The staple cartridge 1040 includes acartridge body 1042 that is configured to be operably seated with theelongate channel 1020. The cartridge body 1042 has an elongate slot 1046therein for accommodating the firing member 1200. The cartridge body1042 further defines an upper surface referred to herein as thecartridge deck 1044. In addition, two lines of staggered stapleapertures 1048 are provided on each side of the elongate slot 1046. Thestaple apertures 1048 operably support corresponding staple drivers 1050that support one or two surgical staples (not shown) thereon. A varietyof such staple driver arrangements are known and may be employed withoutdeparting from the spirit and scope of the various exemplary embodimentsof the invention.

The firing member embodiments also employ a wedge sled assembly 1250 fordriving contact with the staple drivers operably supported within thestaple cartridge 1040. As can be seen in FIG. 60, the wedge sledassembly 1250 includes at least two wedges 1252 that are oriented fordriving contact with the lines of staple drivers operably supportedwithin the staple cartridge 1040. As the firing member 1200 is drivendistally, the wedge sled assembly 1250 travels with the firing member1220 and the wedges 1252 thereon force the drivers 1050 upward towardsthe closed anvil 1100. As the drivers 1050 are driven upwardly, thesurgical staples supported thereon are driven out of their respectiveapertures 1048 into forming contact with the staple forming surface 1104of the closed anvil 1100.

Various exemplary end effector embodiments disclosed herein may alsoemploy a unique and novel firing lockout arrangement that will preventthe clinician from inadvertently advancing or “firing” the firing memberwhen a cartridge is not present, a cartridge has not been properlyseated within the end effector and/or when a spent cartridge remainsinstalled in the end effector. For example, as will be discussed infurther detail below, the firing lockout arrangement may interact withthe implement drive shaft 1300 and/or the firing member 1200 to preventinadvertent advancement of the firing member 1200 when one of theaforementioned conditions exist.

In the illustrated exemplary embodiment, rotation of the implement driveshaft 1300 in a first rotary or “firing” direction will cause the firingmember 1200 to be driven distally through the staple cartridge 1040 ifthe firing member 1200 is properly aligned with the elongate slot 1046in the cartridge body 1042 (FIG. 60), the channel slot 1028 in theelongate channel 1020 and the anvil slot 1103 in the anvil 1100, forexample. Referring primarily to FIG. 90, the elongate slot 1046, thechannel slot 1028 and/or the anvil slot 1103 can guide the firing member1200 as it moves along the path through the surgical end effector 1000,for example, during a firing stroke. When the firing member 1200 is inthe operable configuration, the channel slot 1028 is configured toreceive the foot portion 1206 of the firing member 1200 and the anvilslot 1103 is configured to receive the upper fins 1208 of the firingmember 1200, for example. When a portion of the firing member 1200 ispositioned in the channel slot 1028 and/or the anvil slot 1103, thefiring member 1200 can be aligned or substantially aligned with the axisA. The channel slot 1028 and/or the anvil slot 1103 can guide the firingmember 1200 and maintain the alignment of the firing member 1200 withthe axis A as the firing member 1200 moves from the initial position tothe secondary position relative to the cartridge body 1042, for example.

As was briefly discussed above, in various surgical staple cartridgeexamples, the surgical staples are supported on movable staple driverssupported in the cartridge body. Various exemplary end effectorembodiments employ a wedge sled assembly 1250 that is configured tocontact the staple drivers as the wedge sled assembly is driven distallythrough the staple cartridge to drive the staples out of theirrespective cavities in the cartridge body and into forming contact withthe closed anvil. In at least one exemplary embodiment, the wedge sled1250 is positioned within the staple cartridge 1040. Thus, each newstaple cartridge 1040 has its own wedge sled operably supported therein.When the clinician properly seats a new staple cartridge 1040 into theelongate channel, the wedge sled 1250 is configured to straddle theimplement drive shaft 1300 and engage the firing member 1200 in themanner illustrated in FIGS. 60, 88 and 89, for example. As can be seenin those Figures, the exemplary wedge sled assembly 1250 can comprise asled body 1414, a flange 1410, and wedges 1252. The sled body 1414 canbe positioned around a portion of the implement drive shaft 1300 whenthe wedge sled assembly 1250 is positioned in the elongate channel 1020.The sled body 1414 can be structured such that the sled body 1414 avoidscontact with the implement drive shaft 1300 when the sled body 1414 ispositioned around the implement drive shaft 1300. The sled body 1414 cancomprise a contour 1412, for example, that curves over and/or around theimplement drive shaft 1300. In such embodiment, for example, a flange1410 extends between the sled body 1414 and each of the wedges 1252. Inaddition, the sled body 1414 has a notch 1415 therein that is configuredto receive therein a portion of the firing member body 1203. Referringprimarily to FIG. 89, the flange 1410 can extend substantially parallelto the foot portion 1206 of the firing member 1200 when the firingmember 1200 engages the wedge sled assembly 1250.

When a new staple cartridge 1040 has been properly installed in theelongate channel 1020, initial actuation of the firing member 1200(e.g., by rotating the implement drive shaft 1300) causes a portion ofthe firing member body 1203 to enter the notch 1415 in the wedge sled1250 which thereby results in the alignment of the firing member 1200with the elongate slot 1046 in the cartridge body 1042 (FIG. 60), thechannel slot 1028 in the elongate channel 1020 and the anvil slot 1103in the anvil 1100 to enable the firing member 1250 to be distallyadvanced through the staple cartridge 1040. Hence, the wedge sled mayalso be referred to herein as an “alignment member”. If the staplecartridge 1040 has been improperly installed in the elongate channel,activation of the firing member 1200 will not result in the aligningengagement with the notch 1415 in the wedge sled 1250 and the firingmember 1200 will remain out of alignment with the channel slot 1028 inthe elongate channel 1020 and the anvil slot 1103 in the anvil 1100 tothereby prevent the firing member 1250 from being fired.

After a new staple cartridge 1040 has been properly installed in theelongate channel 1020, the clinician fires the firing member by applyinga first rotary motion to the implement drive shaft 1300. Once the firingmember 1250 has been distally driven through the staple cartridge 1250to its distal-most position, a reverse rotary motion is applied to theimplement drive shaft 1300 to return the firing member 1250 to itsstarting position external to the surgical staple cartridge 1040 toenable the spent cartridge to be removed from the elongate channel 1020and a new staple cartridge to be installed therein. As the firing member1250 is returned to its starting position, the wedge sled 1250 remainsin the distal end of the staple cartridge and does not return with thefiring member 1200. Thus, as the firing member 1200 moves proximally outof the staple cartridge 1040 and the anvil slot 1103 in the anvil, therotary motion of the implement drive shaft 1300 causes the firing member1200 to pivot slightly into an inoperable position. That is, when thefiring member 1200 is in the inoperable position (outside of thecartridge), should the clinician remove the spent cartridge 1040 andfail to replace it with a fresh cartridge containing a new wedge sled1250 and then close the anvil 1110 and attempt to fire the firing member1200, because there is no wedge sled present to align the firing member1200, the firing member 1200 will be unable to advance distally throughthe elongate channel 1020. Thus, such arrangement prevents the clinicianfrom inadvertently firing the firing member 1200 when no cartridge ispresent.

In such exemplary embodiment, the firing member 1200 can besubstantially aligned with an axis A when the firing member 1200 isoriented in an operable configuration such that the firing member 1200can move along a path established through the end effector 1000. Theaxis A can be substantially perpendicular to the staple forming surface1104 of the anvil 1100 and/or the cartridge deck 1044 of the staplecartridge 1040 (FIG. 60). In other exemplary embodiments, the axis A canbe angularly oriented relative to the staple forming surface 1104 of theanvil 1100 and/or the cartridge deck 1044 of the staple cartridge 1040.Further, in at least one exemplary embodiment, the axis A can extendthrough the center of the surgical end effector 1000 and, in otherexemplary embodiments, the axis A can be positioned on either side ofthe center of the surgical end effector 1000.

FIGS. 91-97 illustrate one exemplary form of a surgical end effector1400 that employs a unique and novel firing lockout arrangement. As canbe seen in FIGS. 91-95, when the firing member 1200 is in the initialposition, the firing member 1200 is in an inoperable configuration whichprevents its distal advancement through the end effector due to themisalignment of the firing member 1200 with the channel slot 1028 andthe anvil slot 1103. The firing member 1200 may be retained in theinoperable configuration by a firing lockout generally designated as1418. Referring primarily to FIGS. 91-93, in at least one form, forexample, the firing lockout 1418 includes a first lockout groove ornotch 1402 that is formed in the elongate channel 1020. In otherexemplary embodiments, however, the first lockout notch 1402 can form anopening in the first jaw 1004, the second jaw 1006, the elongate channel1020 and/or the anvil 1100, for example. In various exemplaryembodiments, the first lockout notch 1402 is located in the surgical endeffector 1400 such that the first lockout notch 1402 retainingly engagesa portion of the firing member 1200 when the firing member 1200 is inthe inoperable configuration. The first lockout notch 1402 can be near,adjacent to, and/or connected to the channel slot 1028 in the elongatechannel 1020, for example. Referring primarily to FIG. 91, the channelslot 1028 can have a slot width along the length thereof. In at leastone exemplary embodiment, the first lockout notch 1402 can extend fromthe channel slot 1028 such that the combined width of the channel slot1028 and the first lockout notch 1402 exceeds the slot width of thechannel slot 1028. As can be seen in FIG. 91, when the firing member1200 is in the inoperable configuration, the foot portion 1206 of thefiring member 1200 extends into the first lockout notch 1402 to therebyprevent its inadvertent distal advancement through the elongate channel1020.

When a new staple cartridge 1040 has been properly installed in theelongate channel 1020, initiation of the firing stroke causes the firingmember to engage the wedge sled 1250 positioned within the staplecartridge 1040 which moves the firing member 1200 into driving alignmentwith the elongate slot 1046 in the cartridge body 1042, the channel slot1028 in the elongate channel 1020 and the anvil slot 1103 in the anvil1100 to enable the firing member 1250 to be distally advancedtherethrough. As the firing member 1200 moves from the initial positionto the secondary position relative to the staple cartridge 1040, thefiring member 1200 can move past the first lockout notch 1402, forexample. The first lockout notch 1402 can have a length of approximately0.25 inches, for example. In some other exemplary embodiments, the firstlockout notch 1402 can have a length of approximately 0.15 inches toapproximately 0.25 inches, for example, or of approximately 0.25 inchesto approximately 1.0 inch, for example.

Referring primarily to FIGS. 93 and 94, the surgical end effector 1400can be structured to accommodate the upper fins 1208 of the firingmember 1200 when the firing member 1200 is in the inoperableconfiguration. For example, the firing lockout 1418 can include a secondlockout groove or notch 1404 in the anvil 1100. In the illustratedexemplary embodiment, for example, the second lockout notch 1404 can benear, adjacent to, and/or connected to the anvil slot 1103 in the anvil1100, for example. The anvil slot 1103 can have a slot width along thelength thereof. In at least one exemplary embodiment, the second lockoutnotch 1404 can extend from the anvil slot 1103 such that the combinedwidth of the anvil slot 1103 and the second lockout notch 1404 exceedsthe slot width of the anvil slot 1103. The second lockout notch 1404 canextend a length or distance in the surgical end effector 1400. Thefiring member 1200 can be structured to engage the second lockout notch1404 along the length thereof when the firing member 1200 is in theinoperable configuration. As the firing member 1200 moves from theinitial position to the secondary position relative to the staplecartridge 1040, the firing member 1200 can move past the second lockoutnotch 1404, for example. The second lockout notch 1404 can have a lengthof approximately 0.25 inches, for example. In some other exemplaryembodiments, the second lockout notch 1404 can have a length ofapproximately 0.15 inches to approximately 0.25 inches, for example, orof approximately 0.25 inches to approximately 1.0 inch, for example.Referring primarily to FIG. 93, the first lockout notch 1402 can extendfrom the channel slot 1028 in a first direction X and the second lockoutnotch 1404 can extend from the anvil slot 1103 in a second direction Y.In at least one exemplary embodiment, the first direction X can besubstantially laterally opposite to the second direction Y. In suchexemplary embodiments, the foot portion 1206 of the firing member 1200can pivot into the first lockout notch 1402 and the upper fins 1208 ofthe firing member 1200 can pivot into the second lockout notch 1404 whenthe firing member 1200 moves to the inoperable configuration.

Referring primarily to FIGS. 92-94, when the firing member 1200 isoriented in the inoperable configuration, corresponding portions of thefiring member 1200 engage the first and second lockout notches 1402,1404. The firing member 1200 can be positioned at least partially withinthe first and second lockout notches 1402, 1404 when the firing member1200 is in the inoperable configuration. The firing member 1200 canshift into the first and second lockout notches 1402, 1404 when thefiring member 1200 moves to the inoperable configuration. Further, whenthe firing member 1200 is oriented in the operable configuration, thefiring member 1200 can disengage the first and second lockout notches1402, 1404.

A portion or portions of the surgical end effector 1400 can block thefiring member 1200 and limit or prevent movement of the firing member1200 through the surgical end effector 1400 when the firing member 1200is oriented in the inoperable configuration (see, e.g., FIG. 95). Forexample, the first jaw 1004, the second jaw 1006, the elongate channel1020 and/or the anvil 1100 can be configured to block the firing member1200 when it is in the operable configuration. In some exemplaryembodiments, the first lockout notch 1402 has a first blocking surfaceor edge 1406 (FIGS. 91 and 92) formed thereon and the second lockoutnotch 1404 has a second blocking surface or edge 1408 formed thereon(FIG. 94). Attempts to fire the firing member 1200 while the firingmember 1200 is in the inoperable configuration will result incorresponding portions of the firing member 1200 contacting one or bothof the first and second blocking surfaces 1406, 1408 to prevent thefiring member 1200 from moving from the initial position towards thesecondary positions. In at least one exemplary embodiment, the surgicalend effector 1400 need not have both the first blocking edge 1406 andthe second blocking edge 1408.

FIGS. 97-104 illustrate another exemplary surgical end effectorembodiment 1500 that employs another exemplary firing lockoutarrangement. For example, as can be seen in those Figures, a surgicalend effector 1500 can comprise the elongate channel 1020, the implementdrive shaft 1300, and the firing member 1200. The surgical end effector1500 can also comprise an end effector drive housing 1510 (see, e.g.FIG. 100). Similar to the end effector drive housing 1010 describedherein, the end effector drive housing 1510 can comprise a bearingsleeve 1511 and the third ring gear or housing drive member 768. Thebearing sleeve 1511 can be structured such that the bearing segment 1304of the implement drive shaft 1300 can be moveably positioned in thebearing sleeve 1511. The bearing segment 1304 can move in the bearingsleeve 1511 as the implement drive shaft 1300 moves between aninoperable position and an operable position, as described herein. Thebearing sleeve 1511 can comprise a bore 1512 having an elongatedcross-section such as, for example, a cross-sectional shape comprisingan oval, an ellipse and/or semicircles having longitudinal and/orparallel sides therebetween. In such exemplary embodiments, the bearingsegment 1304 can be positioned against or near a first side of the bore1512 such as, for example, a first semicircle, when the implement driveshaft 1300 is in the inoperable position. Further, the bearing segment1304 can be positioned against or near a second side of the bore 1512such as, for example, a second semicircle, when the implement driveshaft 1300 is in the operable position.

The implement drive shaft 1300 can be moveable between the inoperableposition and the operable position. As described herein, a biasingmember 1520 and/or a portion of the staple cartridge 1040 can move theimplement drive shaft 1300 between the inoperable position and theoperable position, for example. In the illustrated embodiment andothers, the implement drive gear 1302 of the implement drive shaft 1300can be engaged with the third ring gear 768 of the end effector drivehousing 1510 when the implement drive shaft 1300 is in the operableposition. The implement drive gear 1302 can be an external gear, forexample, and the third ring gear 768 can be an internal gear, forexample. The implement drive gear 1302 can move into engagement with thethird ring gear 768 when the implement drive shaft 1300 moves from theinoperable position to the operable position. Further, the implementdrive gear 1302 can be disengaged from the third ring gear 768 when theimplement drive shaft 1300 is in the inoperable position. In at leastone exemplary embodiment, the implement drive gear 1302 can move out ofengagement with the third ring gear 768 when the implement drive shaft1300 moves from the operable position to the inoperable position.Similar to other exemplary embodiments described herein, when theimplement drive shaft 1300 is engaged with the third ring gear 768 inthe end effector drive housing 1510, the drive system 750 (FIG. 61) candrive the firing member 1200 through the elongate channel 1020 of thesurgical end effector 1500, for example, during a firing stroke.

Referring primarily to FIGS. 101 and 102, the bearing segment 1304 canbe positioned against the first side of the bore 1512 of the bearingsleeve 1511 when the implement drive shaft 1300 is in the inoperableposition. A retaining pin 1514 (FIGS. 98, 100, 101 and 103) can bestructured to bias the bearing segment 1304 against the first side ofthe bore 1512 such that the implement drive shaft 1300 is held in theinoperable position, for example, and the implement drive gear 1302 isheld out of engagement with the third ring gear 768, for example. Insome exemplary embodiments, the retaining pin 1514 can be spring-loadedsuch that retaining pin 1514 exerts a force on the bearing segment 1304to move the implement drive shaft 1300 towards the inoperable position.The implement drive shaft 1300 can remain in the inoperable positionuntil another force overcomes the force exerted by the retaining pin1514 to move the implement drive shaft 1300 towards the operableposition, for example, and the implement drive gear 1302 into engagementwith the third ring gear 768, for example.

Referring primarily to FIGS. 103 and 104, the bearing segment 1304 canbe positioned against the second side of the bore 1512 of the bearingsleeve 1511 when the implement drive shaft 1300 is in the operableposition. In various exemplary embodiments, the force exerted by theretaining pin 1514 (FIGS. 98, 100, 101 and 103) can be overcome to movethe bearing segment 1304 against the second side of the bore 1512 suchthat the implement drive shaft 1300 is in the operable position, forexample, and the implement drive gear 1302 is engaged with the thirdring gear 768, for example. As described herein, the biasing element1520 can exert a force on the bearing segment 1304 that overcomes theforce exerted by the retaining pin 1515, for example.

The surgical end effector 1500 can comprise the biasing element 1520,which can be moveable between a first set of positions (see, e.g., FIG.103) and a second set of positions (see, e.g., FIG. 101). The second setof positions can be distal to the first set of positions relative to theend effector drive housing 1510. When the biasing element 1520 is in thefirst set of positions, the biasing element 1520 can be structured tomove the implement drive shaft 1300 to the operable position, forexample. When the biasing element 1520 is in the second set ofpositions, the biasing element 1520 can release the implement driveshaft 1300 such that the implement drive shaft can return to theinoperable position, for example.

The biasing element 1520 can be an independent element positionable inthe surgical end effector 1500. The biasing element 1520 can be moveablyretained in the surgical end effector 1500, for example, and can beoperably engageable with the staple cartridge 1040, for example. Thestaple cartridge 1040 can comprise the biasing element 1520. In someexemplary embodiments, the biasing element 1520 can be integrally formedwith the wedge sled assembly 1250 of the staple cartridge 1040, forexample, and the biasing element 1520 can be moveably retained in thestaple cartridge 1040, for example. In such exemplary embodiments, thebiasing element 1520 can move through the elongate channel 1020 as thewedge sled assembly 1250 and/or the firing member 1200 moves through theelongate channel 1020, for example, during a firing stroke.

Referring primarily to FIG. 99, the biasing element 1520 can comprise abiasing body 1522 and legs 1526 extending from the biasing body 1522.The biasing body 1522 can be positioned around a portion of theimplement drive shaft 1300 in the surgical end effector 1500. In someexemplary embodiments, the biasing body 1522 can be structured such thatthe biasing body 1522 avoids contact with the implement drive shaft 1300when the biasing body 1522 is positioned around the implement driveshaft 1300. The biasing body 1522 can comprise a contour 1524, forexample, that curves over and/or around the implement drive shaft 1300.The legs 1526 can extend along a portion of the elongate channel 1020and/or on either side of the implement drive shaft 1300. The biasingelement 1520 can also comprise at least one extension or wedge 1528. Asdescribed herein, the wedge 1528 can moveably engage the bearing sleeve1511 and/or the bearing segment 1304 to move the implement drive shaftinto the operable position. The biasing element 1520 can also compriseat least one spring 1530. The spring 1530 can be deformable between aninitial configuration (FIG. 101) and deformed configurations (FIG. 103),for example. The spring 1530 can hold the biasing element 1520 in thefirst set of positions relative to the end effector drive housing 1510until a force deforms the spring 1530 from the initial configuration toa deformed configuration. When the spring 1530 moves from the initialconfiguration to the deformed configuration, the biasing element 1520can move from the second set of positions to the first set of positionsrelative to the end effector drive housing 1510.

Referring primarily to FIG. 101, before the insertion of the staplecartridge 1040 (FIG. 103) into the elongate channel 1020, the spring1530 can be in the initial configuration, for example, and the biasingelement 1520 can be in the second set of positions, for example. Theretaining pin 1514 can hold the bearing segment 1304 against the firstside of the bore 1512, for example. In such exemplary embodiments, theimplement drive shaft 1300 can be held in the inoperable position by theretaining pin 1514.

Referring now to FIG. 103, installation of the staple cartridge 1040 inthe elongate channel 1020 moves the biasing element 1520 proximallyagainst the force of springs 1530 into a first set of positions whereinthe wedge 1528 moveably engages the bearing sleeve 1511 and the bearingsegment 1304 to bias the bearing segment 1304 and the implement drivegear 1302 of the implement drive shaft 1300 into meshing engagement withthe third ring gear 768. Thereafter, actuation of the firing drivesystem as described herein will result in the firing of the firingmember 1200. In some exemplary embodiments, a portion of the staplecartridge 1040 is configured to directly contact the biasing element1520 to move the biasing element 1520 to the first set of positions. Inother exemplary embodiments, a portion of the staple cartridge 1040 isconfigured to contact another element in the surgical end effector 1500such as, for example, the firing member 1200, to operable move thebiasing element 1520 to the first set of positions. In still otherexemplary embodiments, the staple cartridge 1040 has the biasing element1520 integrally formed therewith.

In various exemplary embodiments, the biasing element 1520 can movethrough the elongate channel 1020 of the surgical end effector 1500 asthe firing member 1200 and/or the wedge sled assembly 1250 are driventhrough the elongate channel 1020 by the implement drive shaft 1300, forexample, during a firing stroke, as described herein. The biasingelement 1520 can be integrally formed with and/or fixed to the wedgesled assembly 1250 of the staple cartridge 1040. In such exemplaryembodiments, when the staple cartridge 1040 is initially seated in theelongate channel 1020, the wedge sled assembly 1250 and the biasingelement 1520 can be positioned in an initial position relative to thestaple cartridge 1040 and/or the elongate channel 1020. The initialposition of the biasing element 1520 can correspond to the first set ofpositions such that the biasing element 1520 moveably engages thebearing sleeve 1511 of the end effector drive housing 1510 to move theimplement drive shaft 1300 into the operable position, as describedherein. During the firing stroke, the wedge sled assembly 1250 and thebiasing element 1520 can be moved away from the initial or first set ofpositions, for example. The biasing element 1520 can move to the secondset of positions, for example. When the biasing element 1520 moves pastthe first set of positions and into the second set of positions, thebiasing element 1520 may no longer engage the bearing sleeve 1511 of theend effector drive housing 1510 to hold the implement drive shaft 1300in the operable configuration. Though the biasing element 1520 may notbias the implement drive gear 1302 of the implement drive shaft 1300into engagement with the third ring gear 768 when the biasing element1520 moves into the second set of positions, the channel slot 1028, theanvil slot 1103, and/or the elongate slot 1046 in the staple cartridge1040 serve to guide the firing member 1200 in a firing orientation thatretains the implement drive gear 1302 of the implement drive shaft 1300in meshing engagement with the third ring gear 768 and thereby preventsthe implement drive shaft 1300 from returning to the inoperable positionduring the firing stroke.

In at least one exemplary embodiment, the firing member 1200 and/or theimplement drive shaft 1300 can drive the wedge sled assembly 1250 and/orthe biasing element 1520 to the second set of positions during thefiring stroke. In various exemplary embodiments, upon completion of thefiring stroke, the firing member 1200 can return to the initialposition, however, the wedge sled assembly 1250, including the biasingelement 1520, can remain in the second set of positions, for example.The firing member 1200 can return to a proximal position in the surgicalend effector 1500, for example, and the biasing element 1520 can remainin a distal position in the surgical end effector 1500, for example.When the firing member 1200 is in the initial position and the biasingelement 1520 is in the second set of positions, the bearing segment 1304of the implement drive shaft 1300 can shift in the bearing sleeve 1511such that the implement drive shaft 1300 moves into the inoperableposition, for example, and the implement drive gear 1302 moves out ofengagement with the third ring gear 768, for example. In variousexemplary embodiments, the implement drive shaft 1300 can remain in theinoperable position until the biasing element 1520 is drawn back intothe first set of positions and/or until a replacement biasing element1520 is positioned in the first set of positions, for example. Forexample, the spent staple cartridge 1040 is removed from the elongatechannel 1020 and replaced with a replacement staple cartridge 1040,which can comprise a biasing element 1520 located in its firstpositions. When the replacement staple cartridge 1040 is positioned inthe elongate channel 1020, the biasing element 1520 thereof shifts theimplement drive gear 1302 into engagement with the third ring gear 768,for example, and into the operable position, for example. In suchexemplary embodiments, the surgical end effector 1500 can be preventedfrom being re-fired when no cartridge 1040 or a spent cartridge 1040 isseated in the elongate channel 1020. In addition, if the staplecartridge has not been properly seated in the elongate channel 1020 suchthat the biasing element 1520 has not moved the implement drive shaft1300 into meshing engagement with the third ring gear 768, the firingmember 1200 cannot be fired.

As described above, a surgical instrument system can include a surgicalhousing, replaceable end effector assemblies that can be connected tothe surgical housing for use during a surgical technique and thendisconnected from the housing after they have been used, and a motorand/or an actuator configured to fire the end effectors. In variouscircumstances, a surgeon can choose from several different replaceableend effectors for use during a surgical procedure. For example, asurgeon may first select a first replaceable end effector configured tostaple and/or incise a patient's tissue that includes a staple cartridgelength of approximately 15 millimeters (“mm”), for example, to make afirst cut in the patient tissue. In such an embodiment, a cutting bladeand/or a staple-driving sled can be advanced along the approximately 15mm length of the staple cartridge by a drive screw in order to cut andstaple approximately 15 mm of patient tissue. The surgeon may thenselect a second replaceable end effector, also configured to stapleand/or incise patient tissue, which can include a staple cartridgelength of approximately 30 mm to make a second cut in the patient'stissue. In such an embodiment, a cutting blade and/or a staple-drivingsled can be advanced along the approximately 30 mm length of the staplecartridge by a drive screw to cut and staple approximately 30 mm of thepatient's tissue. The surgeon may also select a replaceable end effectorconfigured to staple and/or incise patient tissue that includes a staplecartridge length of approximately 45 mm to make a cut in the patient'stissue, for example. In such an embodiment, a cutting blade and/or astaple driving sled can be advanced along the approximately 45 mm lengthof the staple cartridge by a drive screw to cut and staple approximately45 mm of the patient's tissue. The surgeon may also select a replaceableend effector, which can also be configured to staple and/or incisepatient tissue, which includes a staple cartridge length ofapproximately 60 mm to make a cut in the patient's tissue, for example.In such an embodiment, a cutting blade and/or a staple driving sled canbe advanced along the approximately 60 mm length of the staple cartridgeby a drive screw to cut and staple approximately 60 mm of the patient'stissue. The 15 mm, 30 mm, 45 mm, and/or 60 mm lengths of the endeffectors discussed above are exemplary. Other lengths can be used. Incertain embodiments, a first end effector can include a staple cartridgehaving a length of x, a second end effector can include a staplecartridge having a length of approximately 2*x, a third end effector caninclude a staple cartridge having a length of approximately 3*x, and afourth end effector can include a staple cartridge having a length ofapproximately 4*x, for example.

In some surgical instrument systems utilizing replaceable end effectorshaving different lengths, the drive screws in each of the differentreplaceable end effectors may be identical except that the length ofeach drive screw may be different in order to accommodate the differentlength of the associated replaceable end effector. For example, areplaceable end effector comprising a 30 mm staple cartridge may requirea drive screw which is longer than the drive screw of a replaceable endeffector comprising a 15 mm staple cartridge. In each instance of suchsurgical instrument systems, however, each drive screw which utilizesthe same thread pitch and/or thread lead, described in greater detailbelow, may require the motor to rotate the drive shaft a differentnumber or revolutions depending on the length of the end effector beingused in order for each end effector to be fully fired. For instance, adrive screw providing a 30 mm firing stroke may require twice as manyrevolutions in order to be fully actuated as compared to a drive screwproviding a 15 mm firing stroke. In such surgical instrument systems,electronic communication between the surgical housing and thereplaceable end effector can be utilized to ensure that the electricmotor in the surgical housing turns a correct number of revolutions forthe length of the attached replaceable end effector. For example, areplaceable end effector may include an electronic circuit that can beidentified by the surgical instrument system so that surgical instrumentsystem can turn the motor a correct number of revolutions for theattached end effector. In addition to or in lieu of the above, thereplaceable end effector may include a sensor that senses when an endeffector has been completely actuated. In such an embodiment, the sensorcan be in signal communication with a controller in the housingconfigured to stop the motor when the appropriate signal is received.While suitable for their intended purposes, such electroniccommunication between the surgical housing and the replaceable endeffector may increase the complexity and/or cost of such surgicalinstrument systems.

As outlined above, end effectors having different lengths can be used onthe same surgical instrument system. In the surgical instrument systemsdescribed above, replaceable end effectors having different firinglengths include drive screws that revolve a different number of times toaccommodate the different firing lengths. In order to accommodate thedifferent number of revolutions required for different drive screws, themotor driving the drive screw is operated for a longer duration or ashorter duration, and/or a larger number of revolutions or a smallernumber of revolutions, depending on whether a longer firing length or ashorter firing length is needed. Embodiments of replaceable endeffectors described below enable a surgical instrument system comprisinga motor configured to turn a fixed or set number of revolutions toactuate end effectors having different firing lengths. By operating themotor a fixed number of revolutions, the need for the surgicalinstrument system to identify the length of the end effector may not benecessary. Each end effector in the embodiments described below includesa drive screw with a thread pitch and/or thread lead that enables anactuating portion of an end effector, such as a cutting blade, forexample, to travel the full length of a particular end effector in thefixed number of revolutions of the motor.

Referring to FIG. 105, a drive screw 1700 can be rotated in a firstdirection to move a cutting blade 1730 of an end effector 1740 in adistal direction indicated by arrow E. In use, the drive screw 1700 canbe rotated a fixed or set number of times to advance the cutting blade1730 a full firing length, indicated by length L in FIG. 105. For eachrevolution of the drive screw 1700, in certain embodiments, the cuttingblade 1730 can be moved in the direction of arrow E by an amount equalto the thread pitch, thread lead, and/or distance between adjacentwindings of thread 1708 on the drive screw 1700, described below ingreater detail. In various embodiments, a first drive screw can includea first set of characteristics that defines a first firing length whilea second drive screw can include a second set of characteristics thatdefines a second firing length wherein the first set of characteristicscan be different than the second set of characteristics.

Now referring to FIGS. 106A, 107, 108A, and 109A, further to the above,the distance between thread windings on a drive screw can beproportional to the angle of threads on the drive screw. Putdifferently, the angle at which threads are arranged on a drive screwcan be a characteristic of a drive screw that defines the thread pitchand/or thread lead of the drive screw. A longer drive screw for use in alonger end effector can utilize a larger thread pitch and/or thread leadthan a shorter drive screw for use in a shorter end effector inembodiments where the drive screws, and a motor driving the drivescrews, turn a fixed number of revolutions. The drive screw 1700 in FIG.106A includes a single thread A arranged at an angle α relative to thelongitudinal axis 1701 on the drive screw 1700 wherein the thread Adefines a thread pitch and/or thread lead having a length X. FIG. 106Bshows a cross-sectional view of the drive screw 1700 and the singlethread A. In certain embodiments, the drive screw 1700 may include morethan one thread, as described in greater detail below.

FIG. 107A shows a drive screw 1700′ which can include a first thread A′and a second thread B′. FIG. 107B shows a cross-sectional view of thedrive screw 1700′ wherein the first thread A′ and the second thread B′are positioned approximately 180° out of phase with each other on thedrive screw 1700′. In various embodiments, a drive screw with a firstthread A′ and a second thread B′ can increase the number of threads perunit length compared to a drive screw using a single thread A′ or B′.Where a drive screw includes more than one thread, the distance from awinding of a first thread to an adjacent winding of a second thread isreferred to as “thread pitch.” The distance from one winding of a threadto the next winding of the same thread is referred to as “thread lead.”For a drive screw with a single thread, the thread pitch and the threadlead are the same. For example, and with reference to FIG. 107A, thedistance from a winding of thread A′ to an adjacent winding of thread B′defines the thread pitch of the drive screw 1700′. The distance from awinding of thread A′ to the next winding of thread A′ defines the threadlead of the drive screw 1700′. Thus, the thread lead of the drive screw1700′ in FIG. 107A is equal to X′ and the thread pitch is equal to X′/2.The drive screw 1700 shown in FIGS. 106A and 106B has a single threadand therefore the thread pitch and thread lead are both equal to X. Thethread lead of a drive screw determines the length that a firing member,such as a cutting blade 1730 and/or a staple driver, for example, willtravel for a single revolution of the drive screw.

Returning to FIG. 107A, the first thread A′ and the second thread B′each are arranged at an angle β relative to the longitudinal axis 1701of the drive screw 1700′. Angle β is less than angle α and the threadlead X′ of the drive screw 1700′ in FIG. 107A is greater than the threadlead X of the drive screw 1700 shown in FIG. 106A. For a single rotationof the drive screw 1700′, a cutting blade will move a length X′ alongthe drive screw 1700′. For example, the thread lead X′ can be double thethread pitch or thread lead X of the drive screw 1700 shown in FIG. 106Awherein, as a result, a cutting blade engaged with the drive screw 1700′of FIG. 107A will move twice the distance for a single revolution ofdrive screw 1700′ as would a cutting blade engaged with the drive screw1700 of FIG. 106A.

FIG. 108A shows a drive screw 1700″ which can include a first thread A″,a second thread B″, and a third thread C″ each extending at an angle γrelative to the longitudinal axis 1701 of the drive screw 1700″. FIG.108B is a cross-sectional view of the drive screw 1700″ and shows thethreads A″, B″, and C″ arranged approximately 120° out of phase. Theangle γ is smaller than the angle β in FIG. 107A and the thread lead X″of the drive screw 1700″ in FIG. 108A is greater than the thread lead X′of the drive screw 1700′ shown in FIG. 107A. Similarly, FIG. 109A showsa drive screw 1700′″ which can include a first thread A′″, a secondthread B′″, a third thread C′″, and a fourth thread D′″, each of whichextends at an angle δ relative to the longitudinal axis Z of the drivescrew 1700′″. FIG. 109B is a cross-sectional view of the drive screw1700′″ and shows the threads arranged approximately 90° out of phase.The angle δ is smaller than angle γ and the thread lead X′″ of the drivescrew 1700′″ is larger than that of drive screw 1700″ in FIG. 108A.

An exemplary surgical instrument system may include a housing and amotor in the housing configured to turn a fixed number of revolutionsthat results in a drive screw of a connected replaceable end effectorturning 30 revolutions, for example. The surgical instrument system canfurther include a plurality of replaceable surgical stapler endeffectors, wherein each of the end effectors can include a cutting bladeand/or staple driver driven by the drive screw, for example. In at leastone such embodiment, a first replaceable end effector can include astaple cartridge having a length of 15 mm, for example. The drive screw1700 shown in FIGS. 2A and 2B can be used in the first replaceable endeffector. The thread lead X can be set to 0.5 mm, for example, so thatthe cutting blade and/or staple driver can travel the 15 mm length ofthe staple cartridge in the 30 revolutions of the drive screw 1700. Asecond replaceable end effector can include a staple cartridge having alength of 30 mm, for example, and a drive screw, such as drive screw1700″ illustrated in FIGS. 107A and 107B, for example. The thread leadX′ of the drive screw 1700′ can be set to 1.0 mm, for example, so thatthe cutting blade and/or staple drive can travel the 30 mm length of thestaple cartridge in the 30 revolutions of the drive screw 1700′.Similarly, a third replaceable end effector with a staple cartridgehaving a length of 45 mm, for example, can include a drive screw, suchas drive screw 1700″ in FIGS. 108A and 108B, having a thread lead X″ of1.5 mm, for example, so that the cutting blade and/or staple drivetravels the 45 mm length of the staple deck in the 30 revolutions of thedrive screw 1700″. A fourth replaceable end effector with a staplecartridge having a length of 60 mm, for example can include a drivescrew, such as drive screw 1700′ in FIGS. 109A and 109B, having a threadlead X′″ of 2.0 mm, for example, so that the cutting blade and/or stapledrive travels the 60 mm length of the staple deck in the 30 revolutionsof the drive screw 1700′″.

FIG. 110 shows the cutting blade 1730 of FIG. 105 removed from theremainder of the end effector 1740. The cutting blade 1730 includes apassage 1732 though which the drive screw 1700 passes. Side portions1736 form interior walls of the passage 1732 and can include recesses,such a grooves 1734, for example, which are configured to receivethreads 1708 on the drive screw 1700. The grooves 1734 are oriented atan angle ε that corresponds to the angle of the threads 1708 on thedrive screw 1700. For example, if the threads 1708 are set to the angleα, shown in FIG. 106A, then the angle ε of the grooves 1734 can also beset to the angle α. Correspondingly, the angle ε of the grooves 1734 canbe set to the angles β, δ and/or γ, for example, of the correspondingdrive screw used therewith.

In various embodiments, as illustrated in the exploded view of FIG. 110,the side portions 1736 can be assembled into windows 1738 defined in ashaft portion 1746 of the cutting blade 1730. In certain embodiments, acutting blade 1730 can comprise integral side portions. In at least oneembodiment, the side portions can comprise an appropriate groove angle εmatching an angle of the threads 1708 on a drive screw 1700 which can beformed in the passage 1732 defined therein. Providing a cutting blade1730 with an appropriate groove angle ε for a particular drive screw canbe accomplished in numerous ways. In certain embodiments, a genericcutting blade 1730 can be provided that does not include side portions1736 assembled into the windows 1738 of the shaft portion 1746 thereofwherein various sets of side portions 1736 can be provided such that adesired set of side portions 1736 can be selected from the various setsof side portions 1736 and then assembled to the generic cutting blade1730 so that such an assembly can be used with a specific drive screw.For instance, a first set of side portions 1736, when assembled to thecutting blade 1730, can configure the cutting blade 1730 to be used witha first drive screw and a second set of side portions 1736, whenassembled to the cutting blade 1730, can configure the cutting blade1730 to be used with a second drive screw, and so forth. In certainother embodiments, a cutting blade 1730 can be provided with sideportions formed integrally therewith. In at least one such embodiment,the grooves 1734 can be formed, e.g., with a tap, at the angle ε thatmatches the angle of threads 1708 of a particular drive screw 1700.

FIG. 111 illustrates the drive screw 1700 coupled to a drive shaft 1750via an intermediate gear 1720 disposed therebetween. The drive shaft1750 is turned by a motor. As described above, the motor can complete afixed or set number of revolutions and, as a result, the drive shaft1750 can turn a fixed number of revolutions R. In certain embodiments,the number of revolutions R turned by the drive shaft 1750 may be equalto the fixed number of revolutions turned by the motor. In alternativeembodiments, the number of revolutions R turned by the drive shaft 1750may be greater than or less than the fixed number revolutions turned bythe motor. In various embodiments, one or more gears arranged betweenthe motor and the drive shaft 1750 can cause the drive shaft 1750 tocomplete more revolutions or fewer revolutions than the motor. Incertain embodiments, the drive shaft 1750 can include an external splinegear 1752 surrounding and/or attached to the distal end 1754 of thedrive shaft 1750. The external spline gear 1752 can engage an internalspline gear 1724 defined in the intermediate gear 1720 in order totransmit rotation of the drive shaft 1750 to the intermediate gear 1720.As a result, in at least one embodiment, the intermediate gear 1720 cancomplete the same revolutions R as the drive shaft 1750.

The intermediate gear 1720 can include a second gear 1722 that isengaged to a gear 1712 surrounding and/or attached to a proximal end1702 of the drive screw 1700. The second gear 1722 of the intermediategear 1720 defines a first diameter D1 and the gear 1712 on the proximalend 1702 of the drive screw 1700 defines a second diameter D2. Thesecond diameter D2 can be different than the first diameter D1. When thefirst diameter D1 and the second diameter D2 are different, they candefine a gear ratio that is different than 1:1. As shown in FIG. 111, incertain embodiments, diameter D1 can be larger than diameter D2 suchthat the drive screw 1700 will complete more revolutions R′ than therevolutions R turned by the drive shaft 1750 and the intermediate gear1720. In alternative embodiments, diameter D1 can be smaller thandiameter D2 such that the drive screw 1700 will turn fewer revolutionsR′ than the revolutions R turned by the drive shaft 1750 and theintermediate gear 1720.

The gear ratio between the second gear 1722 of the intermediate gear1720 and the gear 1712 of the drive screw 1700 can be set so that thedrive screw 1700 completes a certain number of revolutions when thedrive shaft 1750 completes its fixed number of revolutions. If theintermediate gear 1722 is part of the replaceable end effector assembly,then the gear ratio between the intermediate gear 1722 and the drivescrew 1700 in each replaceable end effector assembly can be set so thatthe motor in the surgical housing can turn a fixed number ofrevolutions. For example, referring to FIG. 111, assuming that the driveshaft 1750 turns a fixed 30 revolutions and that the replaceablesurgical stapler includes a 15 mm staple cartridge and if the endeffector includes a drive screw with a thread lead of 0.25 mm, then thedrive screw will complete 60 revolutions to advance a cutting bladeand/or a staple driver the 15 mm length of the staple cartridge. In atleast one embodiment, the intermediate gear 1720 can be sized so thatthe second interior gear 1722 has a diameter D1 that is double thediameter D2 of the external gear 1712 of the drive screw 1700. As aresult, the drive screw 1700 will complete 60 revolutions when the driveshaft 1750 completes 30 revolutions. If a second replaceable surgicalstapler includes a 30 mm staple cartridge, then a drive screw with athread lead of 0.25 mm will complete 120 revolutions to advance acutting blade and/or staple driver the 30 mm length. The intermediategear 1720 of the replaceable surgical stapler can be sized so that thesecond interior gear 1722 has a diameter D1 that is four times thediameter D2 of the external gear 1712 of the drive screw 1700. As aresult, the drive screw 1700 will complete 120 revolutions when thedrive shaft 1750 completes 30 revolutions.

Returning to FIG. 105, in certain embodiments, a firing path of thefiring member, e.g., cutting blade 1730, can be linear. In certainembodiments, the firing patch can be curved and/or curvilinear. Incertain embodiments, the drive screw 1708 can be flexible to enable thedrive screw 1708 to follow lateral motions of the firing member along acurved and/or curvilinear path, for example. In certain embodiments, thefiring member can be flexible or can include at least one flexibleportion to enable portions of the firing member to displace laterallyrelative to the drive screw 1708, for example, along a curved and/orcurvilinear path while remaining portions of the firing member are notlaterally displaced relative to the drive screw 1708. In certainembodiments, the firing length may be defined by the distance moved bythe firing member along the firing path regardless of the overall netdisplacement. In various other embodiments, the firing length may bedefined by the overall net displacement of the firing member regardlessof the firing path.

In various embodiments, a kit for use with a surgical instrument systemmay be provided that includes various replaceable end effectors havingdifferent lengths. In certain embodiments, the kit may include aselection of replaceable end effectors having different lengths fromwhich a surgeon may choose for use in a surgical operation on a patient.The kit can also include several replaceable end effectors of eachlength. In certain embodiments, the kit may include a sequence ofreplaceable end effectors of different lengths wherein the sequence ispredetermined for a particular surgical procedure. For example, acertain surgical procedure first may call for a 15 mm incision, then asecond 15 mm incision, and finally a 30 mm incision. A surgical kit forthis surgical procedure can include three replaceable end effectorsconfigured to incise and staple a patient's tissue. The first tworeplaceable end effectors can include an approximately 15 mm length andthe third replaceable end effector can include an approximately 30 mmlength.

FIGS. 112-117 illustrate another exemplary elongate shaft assembly 2200that has another exemplary quick disconnect coupler arrangement 2210therein. In at least one form, for example, the quick disconnect couplerarrangement 2210 includes a proximal coupler member 2212 in the form ofa proximal outer tube segment 2214 that has tube gear segment 354thereon that is configured to interface with the first drive system 350in the above-described manner. As discussed above, the first drivesystem 350 serves to rotate the elongate shaft assembly 2200 and the endeffector 1000 operably coupled thereto about the longitudinal tool axis“LT-LT”. The proximal outer tube segment 2214 has a “necked-down” distalend portion 2216 that is configured to receive a locking tube segment2220 thereon. The quick disconnect arrangement 2210 further includes adistal coupler member 2217 in the form of a distal outer tube portion2218 that is substantially similar to the distal outer tube portion 231described above except that the distal outer tube portion 2218 includesa necked down proximal end portion 2219. A distal outer formation ordovetail joint 2226 is formed on the end of the proximal end portion2219 of the distal outer tube segment 2218 that is configured todrivingly engage a proximal outer formation or dovetail joint 2228 thatis formed on the distal end portion 2216 of the proximal outer tubesegment 2214.

The exemplary embodiment depicted in FIGS. 112-117 employs an exemplaryembodiment of the closure system 670 described above. The quickdisconnect coupler arrangement 2210 is configured to facilitate operablecoupling of proximal closure drive train assemblies to correspondingdistal drive train assemblies. For example, as can be seen in FIG. 113,the elongate shaft assembly 2200 may include a first proximal closuredrive train assembly in the form of a first proximal closure rod segment2230 and a first distal closure drive train assembly in the form of afirst distal closure rod segment 2240 that are configured to be linkedtogether through the quick disconnect coupler arrangement 2210. That is,in at least one exemplary form, the first proximal closure rod segment2230 has a first closure joint formation or dovetail joint segment 2234formed on a distal end 2232 thereof. Likewise, the first distal closurerod segment 2240 has a second closure joint formation or a dovetailjoint segment 2244 formed on a proximal end 2242 thereof that is adaptedto laterally slidably engage the first dovetail joint segment 2234.Still referring to FIG. 113, the elongate shaft assembly 2200 mayinclude a second proximal closure drive train assembly in the form of asecond proximal closure rod segment 2250 and a second distal closuredrive train assembly in the form of a second distal closure rod segment2260 that are configured to be linked together through the quickdisconnect coupler arrangement 2210. That is, in at least one exemplaryform, the second proximal closure rod segment 2250 has a third closurejoint formation or dovetail closure joint segment 2254 formed on adistal end 2252 thereof. Likewise, the distal second distal closure rodsegment 2260 may have a fourth closure joint formation or dovetailclosure joint segment 2264 formed on a proximal end 2262 of the distalsecond closure rod segment 2260 that is adapted to laterally engage thethird dovetail joint segment 2254.

In the illustrated embodiment and others, the first proximal closure rodsegment 2230 and the second proximal closure rod segment 2250 extendthrough the proximal drive shaft segment 380′. The proximal drive shaftsegment 380′ comprises a proximal rotary drive train assembly 387′ andthe distal drive shaft segment 540′ comprises a distal rotary drivetrain assembly 548′. When the proximal rotary drive train assembly 387′is operably coupled to the distal rotary drive train assembly 548′, thedrive shaft assembly 388′ is formed to transmit rotary control motionsto the end effector 1000. In at least one exemplary embodiment, theproximal drive shaft segment 380′ is substantially similar to theproximal drive shaft segment 380 described above, except that the distalend 381′ of the proximal drive shaft segment 380′ has a distal formationor dovetail drive joint 2270 formed thereon. Similarly, the distal driveshaft segment 540′ may be substantially similar to the distal driveshaft segment 540 described above, except that a proximal formationdovetail drive joint 2280 is formed on the proximal end 542′ thereofthat is adapted to drivingly engage the distal dovetail drive joint 2270through the quick disconnect coupler arrangement 2210. The first distalclosure rod segment 2240 and the distal second closure rod segment 2260may also extend through the distal drive shaft segment 540′.

This exemplary embodiment may also include an articulation couplingjoint 2300 that interfaces with the third and fourth drive cables 434,454. As can be seen in FIG. 113, the articulation coupling joint 2300comprises a proximal articulation tube 2302 that has a proximal balljoint segment 2306 formed on a distal end 2304 thereof. The proximalarticulation tube 2302 includes passages 2308 for receiving the cableend portions 434A′, 434B′, 454A′, 454B′ therethrough. A proximal balljoint segment 2310 is movably supported on the proximal ball segment2306. Proximal cable segments 434A′, 434B′, 454A′, 454B′ extend throughpassages 2308 to be attached to the proximal ball joint segment 2310.The proximal articulation tube 2302, the proximal ball joint segment2310 and the proximal cable segments 434A′, 434B′, 454A′, 454B′ may becollectively referred to as a proximal articulation drive train portion2314.

The exemplary articulation coupling joint 2300 may also comprise adistal articulation tube 2320 that has a distal ball joint segment 2324formed on a proximal end 2322 thereof. The distal ball joint segment2324 has a first distal formation or dovetail joint 2325 formed thereonthat is adapted to drivingly engage a first proximal formation ordovetail joint 2307 formed on the proximal ball joint segment 2306 suchthat when the first distal dovetail joint 2325 drivingly engages thefirst proximal dovetail joint 2307, the distal ball joint segment 2324and the proximal ball joint segment 2306 form an internal articulationball assembly. In addition, the articulation coupling joint 2300 furthercomprises a distal ball segment 2330 that is supported on the distalball joint segment 2324 and has a second distal formation or dovetailjoint 2332 formed thereon that is adapted to drivingly engage a secondproximal formation or dovetail joint 2312 on the proximal ball jointsegment 2310. The distal cable segments 444, 445, 446, 447 are attachedto the distal ball segment 2340 and extend through passages 2328 in thedistal articulation tube 2320. When joined together, the proximal balljoint segment 2310 and the distal ball joint segment 2324 form anarticulation ball 2340 that is movably journaled on the internalarticulation ball. The distal articulation tube 2320, the distal ballsegment 2340 and the distal cable segments 444, 445, 446, 4447 may becollectively referred to as a proximal articulation drive train assembly2316.

As can be seen in FIG. 115, the distal portions of the elongate shaftassembly 2200 may be assembled such that the following joint segmentsare retained in registration with each other by the distal coupler 2217or distal outer tube portion 2218 to form a distal dovetail jointassembly generally referred to as 2290: 2226, 2332, 2325, 2280, 2244 and2264. Likewise, the elongate shaft assembly 2200 may be assembled suchthat the proximal coupler member 2212 or proximal outer tube segment2214 retains the following joint segments in registration with eachother to form a proximal dovetail joint assembly generally designated as2292: 2228, 2312, 2307, 2270, 2234 and 2254.

The end effector 1000 may be operably coupled to the elongate shaftassembly 2200 as follows. To commence the attachment, the clinicianmoves the locking tube segment 2220 to a first unlocked position shownin FIGS. 115 and 116. As can be seen in those Figures, the locking tubesegment has an abutment segment 2224 formed on its distal end 2222. Whenin the unlocked position, the abutment segment 2224 protrudes distallybeyond the proximal dovetail joint assembly 2292 to form an abutmentsurface for laterally joining the distal dovetail joint assembly 2290with the proximal dovetail joint assembly 2292. That is, the clinicianmay laterally align the distal dovetail joint assembly 2290 with theproximal dovetail joint assembly 2292 and then slide the distal dovetailjoint assembly 2290 into lateral engagement with the proximal dovetailjoint assembly 2292 until the distal dovetail joint assembly 2290contacts the abutment segment 2224 at which point all of thecorresponding proximal and distal joint segments are simultaneouslyinterconnected. Thereafter, the clinician may move the locking tubesegment 2220 distally to a second locked position as shown in FIG. 117.When in that position, the locking tube segment 2220 covers the quickdisconnect joint 2210 and prevents any relative lateral movement betweenthe distal dovetail assembly 2290 and the proximal dovetail assembly2292.

While the various exemplary embodiments described above are configuredto operably interface with and be at least partially actuated by arobotic system, the end effector and elongate shaft components may beeffectively employed in connection with handheld instruments. Forexample, FIGS. 118-120 depict a handheld surgical instrument 2400 thatmay employ various components and systems described above to operablyactuate an end effector 1000 coupled thereto. In the exemplaryembodiment depicted in FIGS. 118-120, a quick disconnect joint 2210 isemployed to couple the end effector 1000 to the elongate shaft assembly2402. To facilitate articulation of the end effector 1000 about thearticulation joint 700, the proximal portion of the elongate shaftassembly 2402 includes an exemplary manually actuatable articulationdrive 2410.

Referring now to FIGS. 121-123, in at least one exemplary form, thearticulation drive 2410 includes four axially movable articulationslides that are movably journaled on the proximal drive shaft segment380′ between the proximal outer tube segment 2214 and the proximal driveshaft segment 380′. For example, the articulation cable segment 434A′ isattached to a first articulation slide 2420 that has a firstarticulation actuator rod 2422 protruding therefrom. Articulation cablesegment 434B′ is attached to a second articulation slide 2430 that isdiametrically opposite from the first articulation slide 2420. Thesecond articulation slide 2430 has a second articulation actuator rod2432 protruding therefrom. Articulation cable segment 454A′ is attachedto a third articulation slide 2440 that has a third articulationactuator rod 2442 protruding therefrom. Articulation cable segment 454B′is attached to a fourth articulation slide 2450 that is diametricallyopposite to the third articulation slide 2440. A fourth articulationactuator rod 2452 protrudes from the fourth articulation slide 2450.Articulation actuator rods 2422, 2432, 2442, 2452 facilitate theapplication of articulation control motions to the articulation slides2420, 2430, 2440, 2450, respectively by an articulation ring assembly2460.

As can be seen in FIG. 121, the articulation actuator rods 2422, 2432,2442, 2452 movably pass through a mounting ball 2470 that is journaledon a proximal outer tube segment 2404. In at least one embodiment, themounting ball 2470 may be manufactured in segments that are attachedtogether by appropriate fastener arrangements (e.g., welding, adhesive,screws, etc.). As shown in FIG. 109, the articulation actuator rods 2422and 2432 extend through slots 2472 in the proximal outer tube segment2404 and slots 2474 in the mounting ball 2470 to enable the articulationslides 2420, 2430 to axially move relative thereto. Although not shown,the articulation actuator rods 2442, 2452 extend through similar slots2472, 2474 in the proximal outer tube segment 2404 and the mounting ball2470. Each of the articulation actuator rods 2422, 2432, 2442, 2452protrude out of the corresponding slots 2474 in the mounting ball 2470to be operably received within corresponding mounting sockets 2466 inthe articulation ring assembly 2460. See FIG. 122.

In at least one exemplary form, the articulation ring assembly 2460 isfabricated from a pair of ring segments 2480, 2490 that are joinedtogether by, for example, welding, adhesive, snap features, screws, etc.to form the articulation ring assembly 2460. The ring segments 2480,2490 cooperate to form the mounting sockets 2466. Each of thearticulation actuator rods has a mounting ball 2468 formed thereon thatare each adapted to be movably received within a corresponding mountingsocket 2466 in the articulation ring assembly 2460.

Various exemplary embodiments of the articulation drive 2410 may furtherinclude an exemplary locking system 2486 configured to retain thearticulation ring assembly 2460 in an actuated position. In at least oneexemplary form, the locking system 2486 comprises a plurality of lockingflaps formed on the articulation ring assembly 2460. For example, thering segments 2480, 2490 may be fabricated from a somewhat flexiblepolymer or rubber material. Ring segment 2480 has a series of flexibleproximal locking flaps 2488 formed therein and ring segment 2490 has aseries of flexible distal locking flaps 2498 formed therein. Eachlocking flap 2388 has at least one locking detent 2389 formed thereonand each locking flap 2398 has at least one locking detent 2399 thereon.Locking detents 2389, 2399 may serve to establish a desired amount oflocking friction with the articulation ball so as to retain thearticulation ball in position. In other exemplary embodiments, thelocking detents 2389, 2390 are configured to matingly engage variouslocking dimples formed in the outer perimeter of the mounting ball 2470.

Operation of the articulation drive 2410 can be understood fromreference to FIGS. 122 and 123. FIG. 122 illustrates the articulationdrive 2410 in an unarticulated position. In FIG. 123, the clinician hasmanually tilted the articulation ring assembly 2460 to cause thearticulation slide 2420 to move axially in the distal direction “DD”thereby advancing the articulation cable segment 434A′ distally. Suchmovement of the articulation ring assembly 2460 also results in theaxial movement of the articulation slide 2430 in the proximal directionwhich ultimately pulls the articulation cable 434B in the proximaldirection. Such pushing and pulling of the articulation cable segments434A′, 434B′ will result in articulation of the end effector 1000relative to the longitudinal tool axis “LT-LT” in the manner describedabove. To reverse the direction of articulation, the clinician simplyreverses the orientation of the articulation ring assembly 2460 tothereby cause the articulation slide 2430 to move in the distaldirection “DD” and the articulation slide 2420 to move in the proximaldirection “PD”. The articulation ring assembly 2460 may be similarlyactuated to apply desired pushing and pulling motions to thearticulation cable segments 454A′, 454B′. The friction created betweenthe locking detents 2389, 2399 and the outer perimeter of the mountingball serves to retain the articulation drive 2410 in position after theend effector 1000 has been articulated to the desired position. Inalternative exemplary embodiments, when the locking detents 2389, 2399are positioned so as to be received in corresponding locking dimples inthe mounting ball, the mounting ball will be retained in position.

In the illustrated exemplary embodiments and others, the elongate shaftassembly 2402 operably interfaces with a handle assembly 2500. Anexemplary embodiment of handle assembly 2500 comprises a pair of handlehousing segments 2502, 2504 that are coupled together to form a housingfor various drive components and systems as will be discussed in furtherdetail below. See, e.g., FIGS. 118 and 119. The handle housing segments2502, 2504 may be coupled together by screws, snap features, adhesive,etc. When coupled together, the handle segments 2502, 2504 may form ahandle assembly 2500 that includes a pistol grip portion 2506.

To facilitate selective rotation of the end effector 1000 about thelongitudinal tool axis “LT=LT”, the elongate shaft assembly 2402 mayinterface with a first drive system, generally designated as 2510. Thedrive system 2510 includes a manually-actuatable rotation nozzle 2512that is rotatably supported on the handle assembly 2500 such that it canbe rotated relative thereto as well as be axially moved between a lockedposition and an unlocked position.

The surgical instrument 2400 may include a closure system 670 as wasdescribed above for applying opening and closing motions to the anvil1100 of the end effector 1000. In this exemplary embodiment, however,the closure system 670 is actuated by a closure trigger 2530 that ispivotally mounted to the handle frame assembly 2520 that is supportedwithin the handle housing segments 2502, 2504. The closure trigger 2530includes an actuation portion 2532 that is pivotally mounted on a pivotpin 2531 that is supported within the handle frame assembly 2520. SeeFIG. 124. Such exemplary arrangement facilitates pivotal travel towardand away from the pistol grip portion 2506 of the handle assembly 2500.As can be seen in FIG. 124, the closure trigger 2530 includes a closurelink 2534 that is linked to the first pivot link and gear assembly 695by a closure wire 2535. Thus, by pivoting the closure trigger 2530toward the pistol grip portion 2506 of the handle assembly 2500 into anactuated position, the closure link 2534 and closure wire 2535 causesthe first pivot link and gear assembly 695 to move the first closure rodsegment 680 in the distal direction “DD” to close the anvil.

The surgical instrument 2400 may further include a closure triggerlocking system 2536 to retain the closure trigger in the actuatedposition. In at least one exemplary form, the closure trigger lockingsystem 2536 includes a closure lock member 2538 that is pivotallycoupled to the handle frame assembly 2520. As can be seen in FIGS. 125and 126, the closure lock member 2538 has a lock arm 2539 formed thereonthat is configured to ride upon an arcuate portion 2537 of the closurelink 2532 as the closure trigger 2530 is actuated toward the pistol gripportion 2506. When the closure trigger 2530 has been pivoted to thefully actuated position, the lock arm 2539 drops behind the end of theclosure link 2532 and prevents the closure trigger 2530 from returningto its unactuated position. Thus, the anvil 1100 will be locked in itsclosed position. To enable the closure trigger 2530 to return to itsunactuated position and thereby result in the movement of the anvil fromthe closed position to the open position, the clinician simply pivotsthe closure lock member 2538 until the lock arm 2539 thereof disengagesthe end of the closure link 2532 to thereby permit the closure link 2532to move to the unactuated position.

The closure trigger 2532 is returned to the unactuated position by aclosure return system 2540. For example, as can be seen in FIG. 124, oneexemplary form of the closure trigger return system 2540 includes aclosure trigger slide member 2542 that is linked to the closure link2534 by a closure trigger yoke 2544. The closure trigger slide member2542 is slidably supported within a slide cavity 2522 in the handleframe assembly 2520. A closure trigger return spring 2546 is positionedwithin the slide cavity 2520 to apply a biasing force to the closuretrigger slide member 2542. Thus, when the clinician actuates the closuretrigger 2530, the closure trigger yoke 2544 moves the closure triggerslide member 2542 in the distal direction “DD” compressing the closuretrigger return spring 2546. When the closure trigger locking system 2536is disengaged and the closure trigger is released 2530, the closuretrigger return spring 2546 moves the closure trigger slide member 2542in the proximal direction “PD” to thereby pivot the closure trigger 2530into the starting unactuated position.

The surgical instrument 2400 can also employ any of the variousexemplary drive shaft assemblies described above. In at least oneexemplary form, the surgical instrument 2400 employs a second drivesystem 2550 for applying rotary control motions to a proximal driveshaft assembly 380′. See FIG. 128. The second drive system 2550 mayinclude a motor assembly 2552 that is operably supported in the pistolgrip portion 2506. The motor assembly 2552 may be powered by a batterypack 2554 that is removably attached to the handle assembly 2500 or itmay be powered by a source of alternating current. A second drive gear2556 is operably coupled to the drive shaft 2555 of the motor assembly2552. The second drive gear 2556 is supported for meshing engagementwith a second rotary driven gear 2558 that is attached to the proximaldrive shaft segment 380′ of the drive shaft assembly. In at least oneform, for example, the second drive gear 2556 is also axially movable onthe motor drive shaft 2555 relative to the motor assembly 2552 in thedirections represented by arrow “U” in FIG. 128. A biasing member, e.g.,a coil spring 2560 or similar member, is positioned between the seconddrive gear 2556 and the motor housing 2553 and serves to bias the seconddrive gear 2556 on the motor drive shaft 2555 into meshing engagementwith a first gear segment 2559 on the second driven gear 2558.

The second drive system 2550 may further include a firing triggerassembly 2570 that is movably, e.g., pivotally attached to the handleframe assembly 2520. In at least one exemplary form, for example, thefiring trigger assembly 2570 includes a first rotary drive trigger 2572that cooperates with a corresponding switch/contact (not shown) thatelectrically communicates with the motor assembly 2552 and which, uponactivation, causes the motor assembly 2552 to apply a first rotary drivemotion to the second driven gear 2558. In addition, the firing triggerassembly 2570 further includes a retraction drive trigger 2574 that ispivotal relative to the first rotary drive trigger. The retraction drivetrigger 2574 operably interfaces with a switch/contact (not shown) thatis in electrical communication with the motor assembly 2552 and which,upon activation, causes the motor assembly 2552 to apply a second rotarydrive motion to the second driven gear 2558. The first rotary drivemotion results in the rotation of the drive shaft assembly and theimplement drive shaft in the end effector to cause the firing member tomove distally in the end effector 1000. Conversely, the second rotarydrive motion is opposite to the first rotary drive motion and willultimately result in rotation of the drive shaft assembly and theimplement drive shaft in a rotary direction which results in theproximal movement or retraction of the firing member in the end effector1000.

The illustrated embodiment also includes a manually actuatable safetymember 2580 that is pivotally attached to the closure trigger actuationportion 2532 and is selectively pivotable between a first “safe”position wherein the safety member 2580 physically prevents pivotaltravel of the firing trigger assembly 2570 and a second “off” position,wherein the clinician can freely pivot the firing trigger assembly 2570.As can be seen in FIG. 124, a first dimple 2582 is provided in theclosure trigger actuation portion 2532 that corresponds to the firstposition of the safety member 2580. When the safety member 2580 is inthe first position, a detent (not shown) on the safety member 2580 isreceived within the first dimple 2582. A second dimple 2584 is alsoprovided in the closure trigger actuation portion 2532 that correspondsto the second position of the safety member 2580. When the safety member2580 is in the second position, the detent on the safety member 2580 isreceived within the second dimple 2582.

In at least some exemplary forms, the surgical instrument 2400 mayinclude a mechanically actuatable reversing system, generally designatedas 2590, for mechanically applying a reverse rotary motion to theproximal drive shaft segment 380′ in the event that the motor assembly2552 fails or battery power is lost or interrupted. Such mechanicalreversing system 2590 may also be particularly useful, for example, whenthe drive shaft system components operably coupled to the proximal driveshaft segment 380′ become jammed or otherwise bound in such a way thatwould prevent reverse rotation of the drive shaft components under themotor power alone. In at least one exemplary form, the mechanicallyactuatable reversing system 2590 includes a reversing gear 2592 that isrotatably mounted on a shaft 2524A formed on the handle frame assembly2520 in meshing engagement with a second gear segment 2562 on the seconddriven gear 2558. See FIG. 126. Thus, the reversing gear 2592 freelyrotates on shaft 2524A when the second driven gear 2558 rotates theproximal drive shaft segment 380′ of the drive shaft assembly.

In various exemplary forms, the mechanical reversing system 2590 furtherincludes a manually actuatable driver 2594 in the form of a lever arm2596. As can be seen in FIGS. 129 and 130, the lever arm 2596 includes ayoke portion 2597 that has elongate slots 2598 therethrough. The shaft2524A extends through slot 2598A and a second opposing shaft 2598Bformed on the handle housing assembly 2520 extends through the otherelongate slot to movably affix the lever arm 2596 thereto. In addition,the lever arm 2596 has an actuator fin 2597 formed thereon that canmeshingly engage the reversing gear 2592. There is a detent orinterference that keeps the lever arm 2596 in the unactuated state untilthe clinician exerts a substantial force to actuate it. This keeps itfrom accidentally initiating if inverted. Other embodiments may employ aspring to bias the lever arm into the unactuated state. Variousexemplary embodiments of the mechanical reversing system 2590 furtherincludes a knife retractor button 2600 that is movably journaled in thehandle frame assembly 2520. As can be seen in FIGS. 129 and 130, theknife retractor button 2600 includes a disengagement flap 2602 that isconfigured to engage the top of the second drive gear 2556. The kniferetractor button 2600 is biased to a disengaged position by a kniferetractor spring 2604. When in the disengaged position, thedisengagement flap 2602 is biased out of engagement with the seconddrive gear 2556. Thus, until the clinician desires to activate themechanical reversing system 2590 by depressing the knife retractorbutton 2600, the second drive gear 2556 is in meshing engagement withthe first gear segment 2559 of the second driven gear 2558.

When the clinician desires to apply a reverse rotary drive motion to theproximal drive shaft segment 380′, the clinician depresses the kniferetractor button 2600 to disengage the first gear segment 2559 on thesecond driven gear 2558 from the second drive gear 2556. Thereafter, theclinician begins to apply a pivotal ratcheting motion to the manuallyactuatable driver 2594 which causes the gear fin 2597 thereon to drivethe reversing gear 2592. The reversing gear 2592 is in meshingengagement with the second gear segment 2562 on the second driven gear2558. Continued ratcheting of the manually actuatable driver 2594results in the application of a reverse rotary drive motion to thesecond gear segment 2562 and ultimately to the proximal drive shaftsegment 380′. The clinician may continue to ratchet the driver 2594 foras many times as are necessary to fully release or reverse theassociated end effector component(s). Once a desired amount of reverserotary motion has been applied to the proximal drive shaft segment 380′,the clinician releases the knife refractor button 2600 and the driver2594 to their respective starting or unactuated positions wherein thefin 2597 is out of engagement with the reversing gear 2592 and thesecond drive gear 2556 is once again in meshing engagement with thefirst gear segment 2559 on the second driven gear 2558.

The surgical instrument 2400 can also be employed with an end effector1000 that includes a rotary transmission 750 as was described in detailabove. As discussed above, when the drive shaft assembly is in a firstaxial position, rotary motion applied thereto results in the rotation ofthe entire end effector 1000 about the longitudinal tool axis “LT-LT”distal to the articulation joint 700. When the drive shaft assembly isin the second position, rotary motion applied thereto results in therotation of the implement drive shaft which ultimately causes theactuation of the firing member within the end effector 1000.

The surgical instrument 2400 may employ a shifting system 2610 forselectively axially shifting the proximal drive shaft segment 380′ whichmoves the shaft gear 376 into and out of meshing engagement with thefirst rotary driven gear 374. For example, the proximal drive shaftsegment 380′ is movably supported within the handle frame assembly 2520such that the proximal drive shaft segment 380′ may move axially androtate therein. In at least one exemplary form, the shifting system 2610further includes a shifter yoke 2612 that is slidably supported by thehandle frame assembly 2520. See FIGS. 124 and 127. The proximal driveshaft segment 380′ has a pair of collars 386 (shown in FIGS. 124 and128) thereon such that shifting of the shifter yoke 2612 on the handleframe assembly 2520 results in the axial movement of the proximal driveshaft segment 380′. In at least one form, the shifting system 2610further includes a shifter button assembly 2614 operably interfaces withthe shifter yoke 2612 and extends through a slot 2505 in the handlehousing segment 2504 of the handle assembly 2500. See FIGS. 135 and 136.A shifter spring 2616 is mounted with the handle frame assembly 2520such that it engages the proximal drive shaft segment 380′. See FIGS.127 and 134. The spring 2616 serves to provide the clinician with anaudible click and tactile feedback as the shifter button assembly 2614is slidably positioned between the first axial position depicted in FIG.135 wherein rotation of the drive shaft assembly results in rotation ofthe end effector 1000 about the longitudinal tool axis “LT-LT” relativeto the articulation joint 700 (illustrated in FIG. 67) and the secondaxial position depicted in FIG. 136 wherein rotation of the drive shaftassembly results in the axial movement of the firing member in the endeffector (illustrated in FIG. 66). Thus, such arrangement enables theclinician to easily slidably position the shifter button assembly 2614while holding the handle assembly 2500.

FIGS. 137-147 illustrate a lockable articulation joint 2700 that, in oneexemplary embodiment, is substantially identical to the articulationjoint 700 described above except for the differences discussed below. Inone exemplary embodiment, the articulation joint 2700 is locked andunlocked by an articulation lock system 2710. The articulation joint2700 includes a proximal socket tube 702 that is attached to the distalend 233 of the distal outer tube portion 231 and defines a proximal ballsocket 704 therein. See FIG. 137. A proximal ball member 706 that isattached to an intermediate articulation tube segment 712 is movablyseated within the proximal ball socket 704 within the proximal sockettube 702. As can be seen in FIG. 137, the proximal ball member 706 has acentral drive passage 708 that enables the distal drive shaft segment540 to extend therethrough. In addition, the proximal ball member 706has four articulation passages 710 therein which facilitate the passageof distal cable segments 444, 445, 446, 447 therethrough. As can befurther seen in FIG. 137, the intermediate articulation tube segment 712has an intermediate ball socket 714 formed therein. The intermediateball socket 714 is configured to movably support therein an end effectorball 722 formed on an end effector connector tube 720. The distal cablesegments 444, 445, 446, 447 extend through cable passages 724 formed inthe end effector ball 722 and are attached thereto by lugs 726 receivedwithin corresponding passages 728 in the end effector ball 722. Otherattachment arrangements may be employed for attaching distal cablesegments 444, 445, 446, 447 to the end effector ball 722.

As can be seen in FIG. 137, one exemplary form of the articulation locksystem 2710 includes a lock wire or member 2712 that extends through thedistal outer tube portion 231 of elongate shaft assembly and theproximal socket tube 702. The lock wire 2712 has a proximal end 2720that is attached to a transfer disc 2722 that is operably supported inthe handle portion 2500 (generally represented in broken lines in FIG.137). For example, the transfer disc 2722 is mounted on a spindle shaft2724 that is coupled to a boss 2726 formed in the handle 2500. Anactuator cable or wire 2730 is attached to the transfer disc 2722 andmay be manually actuated (i.e., pushed or pulled) by the clinician. Inother embodiments wherein the surgical instrument is attached to therobotic system, the actuator cable 2730 may be configured to receivecontrol motions from the robotic system to actuate the transfer disc2722.

As can be seen in FIGS. 143-146, the lock wire 2712 has a pair ofunlocking wedges 2714, 2716 formed on its distal end 2715. The firstunlocking wedge 2714 is configured to operably interface with the ends2742, 2744 of a distal locking ring 2740 that is journaled on theintermediate articulation tube 712. In its normal “locked” state asshown in FIG. 143, the distal locking ring 2740 applies acircumferentially-extending locking or squeezing force to theintermediate articulation tube 712 to squeeze the intermediatearticulation tube 712 onto the end effector ball 722 to prevent itsmovement within the socket 714. As can be seen in FIGS. 143-146, theends 2742, 2744 of the distal locking ring 2740 are tapered to define aconical or V-shaped opening 2746 therebetween configured to receive thefirst unlocking wedge 2714 therebetween.

As can be further seen in FIGS. 143-146, the second locking wedge 2716is configured to interface with the ends 2752, 2754 of a proximallocking ring 2750 that is journaled on the proximal socket tube 702. Inits normal “locked” state as shown in FIG. 143, the proximal lockingring 27450 applies a circumferentially-extending locking or squeezingforce to the proximal socket tube 702 to squeeze the proximal sockettube 702 onto the proximal ball member 706 to prevent its movementwithin the proximal ball socket 704. As can be seen in FIGS. 143-146,the ends 2752, 2754 of the proximal locking ring 2750 are tapered todefine a conical or V-shaped opening 2756 therebetween configured toreceive the second unlocking wedge 2716 therebetween.

When the articulation joint 2700 is unlocked by actuation thearticulation lock system 2710, the end effector 1000 may be selectivelyarticulated in the various manners described above by actuating thedistal cable segments 444, 445, 446, 447. Actuation of the articulationlock system 2710 may be understood from reference to FIGS. 138, 139 and143-146. FIG. 143 depicts the positions of the first and secondunlocking wedges 2714, 2716 with respect to the distal and proximallocking rings 2740, 2750. When in that state, locking ring 2740 preventsmovement of the end effector ball 722 within the socket 714 and thelocking ring 2750 prevents the proximal ball member 706 from movingwithin socket 704. To unlock the articulation joint 2700, the actuationcable 2726 is pulled in the proximal direction “PD” which ultimatelyresults in the locking wire 2712 being pushed in the distal direction“DD” to the position shown in FIG. 144. As can be seen in FIG. 144, thefirst unlocking wedge 2714 has moved distally between the ends 2742,2744 of the distal locking ring 2740 to spread the ring 2740 to relievethe squeezing force applied to the intermediate articulation tube 712 topermit the end effector ball 722 to move within the socket 714.Likewise, the second unlocking wedge 2716 has moved distally between theends 2752, 2754 of the proximal locking ring 2750 to spread the ring2750 to relieve the squeezing force on the proximal socket tube 702 topermit the proximal ball member 706 to move within the socket 704. Whenin that unlocked position, the articulation system may be actuated toapply actuation motions to the distal cable segments 444, 445, 446, 447in the above described manners to articulate the end effector 1000 asillustrated in FIGS. 138 and 139. For example, FIGS. 143 and 144illustrate the position of the first and second locking wedges 2714,2716 when the end effector 1000 has been articulated into the positionillustrated in FIG. 138. Likewise, FIGS. 145, 146 illustrate theposition of the first and second locking wedges 2714, 2716 when the endeffector 1000 has been articulated into the position illustrated in FIG.139. Once the clinician has articulated the end effector to the desiredposition, the clinician (or robotic system) applies a pushing motion tothe actuation cable to rotate the transfer disc 2722 and move thelocking wire 2712 to the position shown in FIGS. 143, 145 to therebypermit the locking rings 2740, 2750 to spring to their clamped or lockedpositions to retain the end effector 1000 in that locked position.

FIGS. 148-156 illustrate another end effector embodiment 2800 that, inone exemplary form, is substantially identical to the end effector 1000except for the differences discussed below. The end effector 2800includes an anvil assembly 2810 that is opened and closed by applying arotary closure motion thereto. The anvil assembly 2810 is pivotallysupported on an elongate channel 2830 for selective movement between anopen position (FIGS. 148 and 149) and a closed position (FIGS. 150-153).The elongate channel 2830 may be substantially identical to elongatechannel 1020 described above, except for the differences discussedbelow. For example, in the illustrated embodiment, the elongate channel2830 has an end effector connector housing 2832 formed thereon that maybe coupled to an end effector connector tube 720 by the ring-likebearing 734 as described above. As can be seen in FIG. 148, the endeffector connector housing 2832 operably supports a rotary transmissionassembly 2860 therein.

As can be seen in FIGS. 148 and 149, the anvil assembly 2810 includes apair of anvil trunnions 2812 (only one trunnion can be seen in FIG. 148)that are movably received within corresponding trunnion slots 2814formed in the elongate channel 2830. The underside of the anvil assembly2810 further has an anvil open ramp 2816 formed thereon for pivotalengagement with an anvil pivot pin 1201′ on the firing member 1200′.Firing member 1200′ may be substantially identical to firing member 1200described above except for the noted differences. In addition, the anvilassembly 2810 further includes a closure pin 2818 that is configured foroperable engagement with a rotary closure shaft 2910 that receivesrotary closure motions from the rotary transmission assembly 2860 aswill be discussed in further detail below. The firing member 1200′ isrotatably journaled on an implement drive shaft 1300 that is rotatablysupported within an elongate channel 2830 that is configured to supporta surgical staple cartridge therein (not shown). The implement driveshaft 1300 has a bearing segment 1304 formed thereon that is rotatablysupported in a bearing sleeve 2834 formed in the end effector connectorhousing 2832.

In the exemplary illustrated embodiment, the rotary transmissionassembly 2860 includes a rotary drive shaft 2870 that extendslongitudinally through the elongate shaft assembly to operably interfacewith the tool mounting portion (if the end effector 2800 is powered by arobotic system) or with the firing trigger of a handle assembly (if theend effector 2800 is to be manually operated). For those embodimentsemploying an articulation joint, the portion of the rotary drive shaft2870 that extends through the articulation joint 700 may comprise any ofthe flexible drive shaft assemblies disclosed herein. If no articulationjoint is employed, the rotary drive shaft may be rigid. As can be mostparticularly seen in FIGS. 148 and 149 the rotary drive shaft 2870 has arotary drive head 2872 formed thereon or attached thereto that has afirst ring gear 2874 formed thereon. In addition, the rotary drive head2872 further has a second ring gear 2876 formed thereon for selectivemeshing engagement with a shifter gear 2882 attached to a rotary shiftershaft 2880.

The shifter shaft 2880 may comprise any one of the rotary drive shaftassemblies described above and extends through the elongate shaftassembly to operably interface with a tool mounting portion 300 (if theend effector 2800 is driven by a robotic system) or the handle assembly(if the end effector is to be manually operated). In either case, theshifter shaft 2800 is configured to receive longitudinally shiftingmotions to longitudinally shift the shifter gear 2882 within the rotarydrive head 2872 and rotary drive motions to rotate the shifter gear 2882as will be discussed in further detail below.

As can be further seen in FIGS. 148 and 149, the rotary transmissionassembly 2860 further includes a transfer gear assembly 2890 that has abody 2892, a portion of which is rotatably supported within a cavity2873 in the rotary drive head 2872. The body 2892 has a spindle 2894that rotatably extends through a spindle mounting hole 2838 formed in abulkhead 2836 in the end effector connector housing 2832. The body 2892further has a shifter ring gear 2896 formed therein for selectivemeshing engagement with the shifter gear 2882 on the rotary shiftershaft 2880. A transfer gear 2900 is mounted to a transfer gear spindle2902 that protrudes from the body 2892 and is slidably received withinthe arcuate slot 2840 in the bulkhead 2836. See FIGS. 155 and 156. Thetransfer gear 2900 is in meshing engagement with the first ring gear2874 formed in the rotary drive head 2872. As can be seen in FIGS.153-156, the arcuate slot 2840 that has a centrally disposed flexibledetent 2842 protruding therein. The detent 2842 is formed on a web 2844formed by a detent relief slot 2846 formed adjacent to the arcuate slot2840 as shown in FIG. 155.

The rotary closure shaft 2910 has a bearing portion 2912 that isrotatably supported through a corresponding opening in the bulkhead2836. The rotary closure shaft 2910 further has a closure drive gear2914 that is configured for selective meshing engagement with thetransfer gear 2900. The implement drive shaft 1300 also has an implementdrive gear 1302 that is configured for selective meshing engagement withthe transfer gear 2900.

Operation of the end effector 2800 will now be explained with referenceto FIGS. 148-155. FIGS. 148 and 149 illustrate the end effector 2800with the anvil assembly 2810 in the open position. To move the anvilassembly 2810 to the closed position shown in FIG. 150, the shiftershaft 2880 is located such that the shifter gear 2882 is in meshingengagement with the shifter ring gear 2896 in the body 2892. The shiftershaft 2880 may be rotated to cause the body 2892 to rotate to bring thetransfer gear 2900 into meshing engagement with the closure drive gear2914 on the closure shaft 2910. See FIG. 153. When in that position, thelocking detent 2842 retains the transfer gear spindle 2902 in thatposition. Thereafter, the rotary drive shaft 2870 is rotated to applyrotary motion to the transfer gear 2900 which ultimately rotates theclosure shaft 2910. As the closure shaft 2910 is rotated, a rotaryspindle portion 2916 which is in engagement with the closure pin 2818 onthe anvil assembly 2810 results in the anvil assembly 2810 movingproximally causing the anvil assembly 2810 to pivot on the anvil pivotpin 1201′ on the firing member 1200′. Such action causes the anvilassembly 2810 to pivot to the closed position shown in FIG. 150. Whenthe clinician desires to drive the firing member 1200′ distally down theelongate channel 2830, the shifter shaft 2880 is once again rotated topivot the transfer gear spindle 2902 to the position shown in FIG. 154.Again, the locking detent 2842 retains the transfer gear spindle 2902 inthat position. Thereafter, the rotary drive shaft 2870 is rotated toapply rotary motion to the drive gear 1302 on the implement drive shaft1300. Rotation of the implement drive shaft 1300 in one direction causesthe firing member 1200′ to be driven in the distal direction “DD”.Rotation of the implement drive shaft 1300 in an opposite direction willcause the firing member 1200′ to be retracted in the proximal direction“PD”. Thus, in those applications wherein the firing member 1200′ isconfigured to cut and fire staples within a staple cartridge mounted inthe elongate channel 2830, after the firing member 1200′ has been drivento its distal-most position within the elongate channel 2830, the rotarydrive motion applied to the implement drive shaft 1300 by the rotarydrive shaft assembly 2870 is reversed to retract the firing member 1200′back to its starting position shown in FIG. 150. To release the targettissue from the end effector 2800, the clinician again rotates theshifter shaft 2800 to once again bring the transfer gear 2900 intomeshing engagement with the drive gear 2914 on the closure drive shaft2910. Thereafter, a reverse rotary motion is applied to the transfergear 2900 by the rotary drive shaft 2870 to cause the closure driveshaft 2910 to rotate the drive spindle 2916 and thereby cause the anvilassembly 2810 to move distally and pivot to the open position shown inFIGS. 148 and 149. When the clinician desires to rotate the entire endeffector 2800 about the longitudinal tool axis “LT-LT”, the shiftershaft is longitudinally shifted to bring the shifter gear 2882 intosimultaneously meshing engagement with the second ring gear 2876 on therotary drive head 2872 and the shifter ring gear 2896 on the transfergear body 2892 as shown in FIG. 152. Thereafter, rotating the rotarydrive shaft 2880 causes the entire end effector 2800 to rotate about thelongitudinal tool axis “LT-LT” relative to the end effector connectortube 720.

FIGS. 157-170 illustrate another end effector embodiment 3000 thatemploys a pull-type motions to open and close the anvil assembly 3010.The anvil assembly 3010 is movably supported on an elongate channel 3030for selective movement between an open position (FIGS. 168 and 169) anda closed position (FIGS. 157, 160 and 170). The elongate channel 3030may be substantially identical to elongate channel 1020 described above,except for the differences discussed below. The elongate channel 3030may be coupled to an end effector drive housing 1010 in the mannerdescribed above. The end effector drive housing 1010 may also be coupledto an end effector connector tube 720 by the ring-like bearing 734 asdescribed above. As can be seen in FIG. 157, the end effector drivehousing 1010 may support a drive arrangement 748 and rotary transmission750 as described above.

As can be seen in FIG. 160, the anvil assembly 3010 includes a pair ofanvil trunnions 3012 (only one trunnion can be seen in FIG. 160) thatare movably received within corresponding trunnion slots 3032 formed inthe elongate channel 3030. The underside of the anvil assembly 2810further has an anvil open notches 3016 formed thereon for pivotalengagement with the upper fins 1208 on the firing member 3100. See FIG.168. Firing member 3100 may be substantially identical to firing member1200 described above except for the noted differences. In theillustrated embodiment, the end effector 3000 further includes an anvilspring 3050 that is configured to apply a biasing force on the anviltrunnions 3012. One form of anvil spring 3050 is illustrated in FIG.159. As can be seen in that Figure, the anvil spring 3050 may befabricated from a metal wire and have two opposing spring arms 3052 thatare configured to bear upon the anvil trunnions 3012 when the anviltrunnions are received within their respective trunnion slots 3032. Inaddition, as can be further seen in FIG. 159, the anvil spring 3050 hastwo mounting loops 3054 formed therein that are adapted to be movablysupported on corresponding spring pins 3034 formed on the elongatechannel 3030. See FIG. 158. As will be discussed in further detailbelow, the anvil spring 3050 is configured to pivot on the spring pins3034 within the elongate channel 3030. As can be most particularly seenin FIG. 158, a portion 3035 of each side wall of the elongate channel isrecessed to provide clearance for the movement of the anvil spring 3050.

As can be seen in FIGS. 157 and 160-170, the end effector 3000 furtherincludes a closure tube 3060 that is movably supported on the elongatechannel 3030 for selective longitudinal movement thereon. To facilitatelongitudinal movement of the closure tube 3060, the embodiment depictedin FIGS. 157 and 160-170 includes a closure solenoid 3070 that is linkedto the closure tube 3060 by a linkage arm 3072 that is pivotally pinnedor otherwise attached to the closure tube 3030. When the solenoid isactuated, the linkage arm 3072 is driven in the distal direction whichdrives the closure tube 3060 distally on the end of the elongate channel3030. As the closure tube 3060 moves distally, it causes the anvilassembly 3010 to pivot to a closed position. In an alternativeembodiment, the solenoid may comprise an annular solenoid mounted on thedistal end of the end effector drive housing 1010. The closure tubewould be fabricated from a metal material that could be magneticallyattracted and repelled by the annular solenoid to result in thelongitudinal movement of the closure tube.

In at least one form, the end effector 3060 further includes a uniqueanvil locking system 3080 to retain the anvil assembly 3010 locked inposition when it is closed onto the target tissue. In one form, as canbe seen in FIG. 157, the anvil locking system 3080 includes an anvillock bar 3082 that extends transversely across the elongate channel 3030such that the ends thereof are received within corresponding lock barwindows 3036 formed in the elongate channel 3030. See FIG. 158.Referring to FIG. 161, when the closure tube 3060 is in its distal-most“closed” position, the ends of the lock bar 3082 protrude laterally outthrough the lock bar windows 3036 and extend beyond the proximal end ofthe closure tube 3060 to prevent it from moving proximally out ofposition. The lock bar 3082 is configured to engage a solenoid contact3076 supported in the end effector drive housing 1010. The solenoidcontact 3076 is wired to a control system for controlling the solenoid3070. The control system includes a source of electrical power eithersupplied by a battery or other source of electrical power in the roboticsystem or handle assembly, whichever the case may be.

The firing member 3100 is rotatably journaled on an implement driveshaft 1300 that is rotatably supported within an elongate channel 2830that is configured to support a surgical staple cartridge therein (notshown). The implement drive shaft 1300 has a bearing segment 1304 formedthereon that is rotatably supported in a bearing sleeve 2834 formed inthe end effector connector housing 2832 and operably interfaces with therotary transmission 750 in the manner described above. Rotation of theimplement drive shaft 1300 in one direction causes the firing member3100 to be driven distally through the elongate channel 3030 androtation of the implement drive shaft 1300 in an opposite rotarydirection will cause the firing member 1200″ to be refracted in theproximal direction “PD”. As can be seen in FIGS. 157 and 160-170, thefiring member 3100 has an actuation bar 3102 configured to engage thelock bar 3082 as will be discussed in further detail below.

The anvil locking system 3080 further includes an anvil pulling assembly3090 for selectively pulling the anvil into wedging locking engagementwith the closure tube 3060 when the closure tube 3060 has been movedinto its distal-most position wherein the distal end of the closure tube3060 is in contact with an anvil ledge 3013 formed on the anvil assembly3010. In one form, the anvil pulling assembly 3090 includes a pair ofanvil pull cables 3092 that are attached to the proximal end of theanvil assembly 3010 and protrude proximally through the elongate shaftassembly to the tool mounting portion or handle assembly, whichever thecase may be. The pull cables 3092 may be attached to an actuatormechanism on the handle assembly or be coupled to one of the drivesystems on the tool mounting portion that is configured to apply tensionto the cables 3092.

Operation of the end effector 3000 will now be described. FIGS. 168 and169 illustrate the anvil assembly 3010 in an open position. FIG. 168illustrates the firing member 3100 in proximal-most position wherein anew staple cartridge (not shown) may be mounted in the elongate channel3030. The closure tube 3060 is also in its proximal-most unactuatedposition. Also, as can be seen in FIG. 167, when the firing member 3100is in its proximal-most position, the actuation bar 3102 has biased thelock bar into engagement with the solenoid contact 3076 which enablesthe solenoid to be activated for the next closure sequence. Thus, tocommence the closure process, the rotary drive shaft 752 is actuated tomove the firing member 3100 to its starting position illustrated in FIG.169. When in that position, the actuation bar 3102 has moved in theproximal direction sufficiently to enable the lock bar 3082 to move outof engagement with the solenoid contact 3076 such that when power issupplied to the solenoid control circuit, the solenoid link 3072 isextended. Control power is then applied—either automatically or througha switch or other control mechanism in the handle assembly to thesolenoid 3070 which moves the closure tube 3060 distally until thedistal end of the closure tube 3060 contacts the ledge 3013 on the anvilassembly 3010 to cause the anvil assembly to pivot closed on the firingmember 1200″ as shown in FIG. 162. As can be seen in that Figure, thelock bar 3082 is positioned to prevent movement of the closure tube 3060in the proximal direction. When in that position, the clinician thenapplies tension to the pull cables 3092 to pull the proximal end of theanvil assembly 3010 into wedging engagement with the closure tube 3060to lock the anvil assembly 3010 in the closed position. Thereafter, thefiring member 1200″ may be driven in the distal direction through thetissue clamped in the end effector 3000. Once the firing process hasbeen completed. The implement drive shaft is rotated in an oppositedirection to return the firing member 3100 to its starting positionwherein the actuation bar 3102 has once again contacted the lock bar3082 to flex it into contact with the solenoid contact 3076 and to pullthe ends of the lock bar 3082 into the windows 3036 in the elongatechannel 3030. When in that position, when power is supplied to thesolenoid control system, the solenoid 3070 retracts the closure tube3060 in the proximal direction to its starting or open position shown inFIGS. 167 and 168. As the closure tube 3060 moves proximally out ofengagement with the anvil assembly 3010, the anvil spring 3050 applies abiasing force to the anvil trunnions 3012 to bias the anvil assembly tothe open position shown in FIG. 168.

FIGS. 171-178 illustrate another exemplary elongate shaft assembly 3200that has another exemplary quick disconnect coupler arrangement 3210therein. In at least one form, for example, the quick disconnect couplerarrangement 3210 includes a proximal coupler member 3212 in the form ofa proximal outer tube segment 3214 that, in one arrangement, may have atube gear segment 354 thereon that is configured to interface with thefirst drive system 350 in the above-described manner when the device isto be robotically controlled. In another embodiment, however, theproximal outer tube segment 3214 may interface with amanually-actuatable rotation nozzle 2512 mounted to a handle assembly inthe above-described manner. As discussed above, the first drive system350 in a robotically-controlled application or the rotation nozzle 2512in a handheld arrangement serve to rotate the elongate shaft assembly3200 and the end effector operably coupled thereto about thelongitudinal tool axis “LT-LT”. See FIG. 171. The proximal outer tubesegment 3214 has a “necked-down” distal end portion 3216 that isconfigured to receive a locking collar thereon.

In the exemplary embodiment depicted in FIGS. 171-178, the elongateshaft assembly 3200 includes a proximal drive shaft segment 380″ thatmay be substantially identical to the proximal drive shaft segment 380described above except for the differences discussed below and beconfigured to receive rotary and axial control motions from the roboticsystem or handle assembly in the various manners disclosed herein. Theillustrated embodiment may be used with an articulation joint 700 asdescribed above and include articulation cables 434 and 454 that may becoupled to the articulation control drives in the various mannersdescribed herein. A proximal filler material 3220 is provided within theproximal outer tube segment 3214 to provide axial support for thearticulation cable end portions 434A, 434B, 454A, 454B. Eacharticulation cable end portion 434A, 434B, 454A, 454B extends through acorresponding proximal articulation passage 3222 provided through theproximal filler material 3220. Each articulation cable end portion 434A,434B, 454A, 454B further has a proximal articulation clip 3224 attachedthereto that is configured to slide within the correspondingarticulation passage 3222. The proximal articulation clips 3224 may befabricated from metal or polymer material and each have a pair offlexible clip arms 3226 that each have a fastener cleat 3228 formedthereon. Likewise, the proximal drive shaft segment 380″ is movablereceived in a shaft passage 3230 in the proximal filler material 3220. Adrive shaft connection clip 3240 thereon. In one exemplary form, thedrive shaft connection clip 3240 is formed with a central tubularconnector portion 3242 and two flexible clip arms 3244 thereon that eachhave a fastener cleat 3248 thereon.

As can be further seen in FIGS. 171, 172 and 176-178, the quickdisconnect arrangement 3210 further includes a distal coupler member3250 in the form of a distal outer tube segment 3252 that issubstantially similar to the distal outer tube portion 231 describedabove except that the distal outer tube segment 3252 includes a neckeddown proximal end portion 3254. The distal outer tube segment 3252 isoperably coupled to an end effector 1000 of the various types disclosedherein and includes a distal drive shaft segment 540″ that may besubstantially similar to distal drive shaft segment 540 described aboveexcept for the differences noted below. A distal filler material 3260 isprovided within the distal outer tube segment 3252 to provide axialsupport for the distal articulation cable segments 444, 445, 446, 447.Each distal articulation cable segment 444, 445, 446, 447 extendsthrough a corresponding distal articulation passage 3262 providedthrough the distal filler material 3260. Each distal articulation cablesegment 444, 445, 446, 447 further has a distal articulation bayonetpost 3270 attached thereto that is configured to slide between the cliparms 3226 of the corresponding proximal articulation clip 3224. Eachdistal articulation bayonet post 3270 is configured to be retaininglyengaged by the fastener cleats 3228 on the corresponding clip arms 3226.Likewise, the distal drive shaft segment 540″ is movably received in adistal shaft passage 3264 in the distal filler material 3260. A distaldrive shaft bayonet post 3280 is attached to the proximal end of thedistal drive shaft segment 540″ such that it may protrude proximallybeyond the distal articulation bayonet posts 3270. FIG. 172 illustratesthe position of the distal drive shaft bayonet post 3280 (in brokenlines) relative to the distal articulation bayonet posts 3270. Thedistal drive shaft bayonet post 3280 is configured to be retaininglyengaged by the fastener cleats 3248 on the corresponding clip arms 3244on the drive shaft connection clip 3240.

As can be seen in FIGS. 171-178, the exemplary quick disconnect couplerarrangement 3210 further includes an axially movable lock collar 3290that is movably journaled on the necked down proximal end portion 3254of the distal outer tube segment 3252. As can be most particularly seenin FIG. 174, one form of the lock collar 3290 includes an outer locksleeve 3292 that is sized to be slidably received on the necked downportions 3216, 3254 of the proximal outer tube segment 3214 and distalouter tube segment 3254, respectively. The outer lock sleeve 3292 iscoupled to central lock body 3294 by a bridge 3295. The bridge 3295 isconfigured to slide through a distal slot 3255 in the necked downportion 3254 of the distal outer tube segment 3254 as well as a proximalslot 3217 in the necked down portion 3216 of the proximal outer tubesegment 3214 that is slidably received within the necked down proximalend portion 3254 of the distal outer tube segment 3252 and may alsoslidably extend into the necked down portion 3216 of the proximal outertube segment 3214. As can be further seen in FIG. 174, the central lockbody 3294 has a plurality of passages 3296 for receiving thearticulation posts and clips therethrough. Likewise, the central lockbody 3294 has a central drive shaft passage 3298 for movably receivingthe distal drive shaft segment 540″ therein.

Use of the exemplary quick disconnect coupler arrangement 3210 will nowbe described. Referring first to FIGS. 171 and 172, the distal couplermember 3250 is axially aligned with the proximal coupler member 3212such that the bridge 3295 is aligned with the slot 3217 in the neckeddown portion 3216 of the proximal outer tube segment 3214 and the distaldrive shaft bayonet post 3280 is aligned with the central tubularconnector portion 3242 on the proximal drive shaft connector clip 3240.Thereafter, the distal coupler member 3250 is brought into abuttingengagement with the proximal coupler member 3212 to cause the distaldrive shaft bayonet post 3280 to slide into the central tubular segment3214 an ultimately into retaining engagement with the fastener cleats3248 on the proximal drive shaft connector clip 3240. Such action alsocauses each distal articulation bayonet connector post 3270 to beretainingly engaged by the fastener cleats 3228 on the proximalarticulation connector clips 3224 as shown in FIG. 176. It will beappreciated that as the distal drive shaft bayonet post 3280 is insertedbetween the clip arms 3244, the clip arms 3244 flex outward until thefastener cleats 3248 engage a shoulder 3281 on the post 3280. Likewise,as each of the distal articulation bayonet posts 3270 are insertedbetween their corresponding connector arms 3226, the connector arms 3226flex outward until the fastener cleats 3228 engage a shoulder 3271 onthe post 3270. Once the distal drive shaft segment 540″ has beenconnected to the proximal drive shaft segment 380″ and the distalarticulation cable segments 444, 445, 446, 447 have been connected tothe articulation cable end portions 434A, 434B, 454A, 454B,respectively, the user may then slide the outer lock sleeve 3292proximally to the position shown in FIGS. 177 and 178. When in thatposition, the central lock body 3294 prevents the clip arms 3244, 3226from flexing outward to thereby lock the distal coupler member 3250 tothe proximal coupler member 3212. To disconnect the distal couplermember 3250 from the proximal coupler member 3212, the user moves theouter lock sleeve 392 to the position shown in FIGS. 175 and 176 andthereafter pulls the coupler members 3250, 3212 apart. As opposing axialseparation motions are applied to the coupler members 3250, 3212, theclip arms 3244 and 3226 are permitted to flex out of engagement with thedistal drive shaft bayonet post and the distal articulation bayonetposts, respectively.

Non-Limiting Examples

One exemplary form comprises a surgical tool for use with a roboticsystem that includes a tool drive assembly that is operatively coupledto a control unit of the robotic system that is operable by inputs froman operator and is configured to robotically-generate output motions. Inat least one exemplary form, the surgical tool includes a drive systemthat is configured to interface with a corresponding portion of the tooldrive assembly of the robotic system for receiving therobotically-generated output motions therefrom. A drive shaft assemblyoperably interfaces with the drive system and is configured to receivethe robotically-generated output motions from the drive system and applycontrol motions to a surgical end effector that operably interfaces withthe drive shaft assembly. A manually-actuatable control system operablyinterfaces with the drive shaft assembly to selectively applymanually-generated control motions to the drive shaft assembly.

In connection with another general exemplary form, there is provided asurgical tool for use with a robotic system that includes a tool driveassembly that is operatively coupled to a control unit of the roboticsystem that is operable by inputs from an operator and is configured toprovide at least one rotary output motion to at least one rotatable bodyportion supported on the tool drive assembly. In at least one exemplaryform, the surgical tool includes a surgical end effector that comprisesat least one component portion that is selectively movable between firstand second positions relative to at least one other component portionthereof in response to control motions applied thereto. An elongateshaft assembly is operably coupled to the surgical end effector andcomprises at least one gear-driven portion that is in operablecommunication with the at least one selectively movable componentportion. A tool mounting portion is operably coupled to the elongateshaft assembly and is configured to operably interface with the tooldrive assembly when coupled thereto. At least one exemplary form furthercomprises a tool mounting portion that comprises a driven element thatis rotatably supported on the tool mounting portion and is configuredfor driving engagement with a corresponding one of the at least onerotatable body portions of the tool drive assembly to receivecorresponding rotary output motions therefrom. A drive system is inoperable engagement with the driven element to applyrobotically-generated actuation motions thereto to cause thecorresponding one of the at least one gear driven portions to apply atleast one control motion to the selectively movable component. Amanually-actuatable reversing system operably interfaces with theelongate shaft assembly to selectively apply manually-generated controlmotions thereto.

In accordance with another exemplary general form, there is provided asurgical tool for use with a robotic system that includes a tool driveassembly that is operatively coupled to a control unit of the roboticsystem that is operable by inputs from an operator and is configured torobotically-generate rotary output motions. In at least one exemplaryform, the surgical tool comprises a rotary drive system that isconfigured to interface with a corresponding portion of the tool driveassembly of the robotic system for receiving the robotically-generatedrotary output motions therefrom. A rotary drive shaft assembly operablyinterfaces with the rotary drive system and is configured to receive therobotically-generated rotary output motions from the rotary drive systemand apply rotary drive motions to a surgical end effector operably thatinterfaces with the rotary drive shaft assembly. A manually-actuatablereversing system operably interfaces with the rotary drive shaftassembly to selectively apply manually-generated rotary drive motions tothe rotary drive shaft assembly.

Another exemplary form comprises a surgical stapling device thatincludes an elongate shaft assembly that has a distal end and defines alongitudinal tool axis. The device further includes an end effector thatcomprises an elongate channel assembly that includes a portion that isconfigured to operably support a surgical staple cartridge therein. Ananvil is movably supported relative to the elongate channel assembly.The surgical stapling device further comprises a rotary joint thatcouples the elongate channel assembly to the distal end of the elongateshaft assembly to facilitate selective rotation of the elongate channelassembly about the longitudinal tool axis relative to the distal end ofthe elongate shaft assembly.

Another exemplary form comprises a rotary support joint assembly forcoupling a first portion of a surgical instrument to a second portion ofa surgical instrument. In at least one exemplary form, the rotarysupport joint assembly comprises a first annular race in the firstportion and a second annular race in the second portion and which isconfigured for substantial registration with the first annular race whenthe second portion is joined with the first portion. A ring-like bearingis supported within the registered first and second annular races.

In connection with another exemplary general form, there is provided arotary support joint assembly for coupling a surgical end effector to anelongate shaft assembly of a surgical instrument. In at least oneexemplary form, the rotary support joint assembly comprises acylindrically-shaped connector portion on the surgical end effector. Afirst annular race is provided in the perimeter of the connectorportion. A socket is provided on the elongate shaft and is sized toreceive the cylindrically-shaped connector portion therein such that thecylindrically-shaped connector portion may freely rotate relative to thesocket. A second annular race is provided in an inner wall of the socketand is configured for substantial registration with the first annularrace when the cylindrically-shaped connector portion is received withinthe socket. A window is provided in the socket in communication with thesecond annular race. A ring-like bearing member that has a free end isinsertable through the window into the first and second registeredannular races.

In connection with another exemplary general form, there is provided amethod for rotatably coupling a first portion of a surgical instrumentto a second portion of a surgical instrument. In various exemplaryforms, the method comprises forming a first annular race in the firstportion and forming a second annular race in the second portion. Themethod further includes inserting the first portion into the secondportion such that the first and second annular races are in substantialregistration and inserting a ring-like bearing within the registeredfirst and second annular races.

Another exemplary form comprises a drive shaft assembly for a surgicalinstrument that includes a plurality of movably interlocking jointsegments that are interconnected to form a flexible hollow tube. Aflexible secondary constraining member is installed in flexibleconstraining engagement with the plurality of movably interlocking jointsegments to retain the interlocking joint segments in movableinterlocking engagement while facilitating flexing of the drive shaftassembly.

In accordance with another general exemplary form, there is provided acomposite drive shaft assembly for a surgical instrument that includes aplurality of movably interlocking joint segments that are cut into ahollow tube by a laser and which has a distal end and a proximal end. Aflexible secondary constraining member is in flexible constrainingengagement with the plurality of movably interlocking joint segments toretain the interlocking joint segments in movable interlockingengagement while facilitating flexing of the drive shaft assembly.

In accordance with yet another exemplary general form, there is provideda drive shaft assembly for a surgical instrument that includes aplurality of movably interconnected joint segments wherein at least somejoint segments comprise a ball connector portion that is formed from sixsubstantially arcuate surfaces. A socket portion is sized to movablyreceive the ball connector portion of an adjoining joint segmenttherein. A hollow passage extends through each ball connector portion toform a passageway through the drive shaft assembly. The drive shaftassembly may further include a flexible secondary constraining memberinstalled in flexible constraining engagement with the plurality ofmovably interconnected joint segments to retain the joint segments inmovable interconnected engagement while facilitating flexing of thedrive shaft assembly.

Another exemplary form comprises a method of forming a flexible driveshaft assembly for a surgical instrument. In various exemplaryembodiments, the method comprises providing a hollow shaft and cutting aplurality of movably interconnected joint segments into the hollow shaftwith a laser. The method further comprises installing a secondaryconstraining member on the hollow shaft to retain the movablyinterconnected joint segments in movable interconnected engagement whilefacilitating flexing of the drive shaft assembly.

In connection with another exemplary form, there is provided a method offorming a flexible drive shaft assembly for a surgical instrument. In atleast one exemplary embodiment, the method comprises providing a hollowshaft and cutting a plurality of movably interconnected joint segmentsinto the hollow shaft with a laser. Each joint segment comprises a pairof opposing lugs wherein each lug has a tapered outer perimeter portionthat is received within a corresponding socket that has a tapered innerwall portion which cooperates with the tapered outer perimeter portionof the corresponding lug to movably retain the corresponding lugtherein.

Another exemplary general form comprises a rotary drive arrangement fora surgical instrument that has a surgical end effector operably coupledthereto. In one exemplary form, the rotary drive arrangement includes arotary drive system that is configured to generate rotary drive motions.A drive shaft assembly operably interfaces with the rotary drive systemand is selectively axially movable between a first position and a secondposition. A rotary transmission operably interfaces with the drive shaftassembly and the surgical end effector such that when the drive shaftassembly is in the first axial position, application of one of therotary drive motions to the drive shaft assembly by the rotary drivesystem causes the rotary transmission to apply a first rotary controlmotion to the surgical end effector and when the drive shaft assembly isin the second axial position, application of the rotary drive motion tothe drive shaft assembly by the rotary drive system causes the rotarytransmission to apply a second rotary control motion to the surgical endeffector.

In connection with another exemplary general form, there is provided asurgical tool for use with a robotic system that includes a tool driveassembly that is operatively coupled to a control unit of the roboticsystem that is operable by inputs from an operator and is configured togenerate output motions. In at least one exemplary form the surgicaltool comprises a tool mounting portion that is configured operablyinterface with a portion of the robotic system. A rotary drive system isoperably supported by the tool mounting portion and interfaces with thetool drive assembly to receive corresponding output motions therefrom.An elongate shaft assembly operably extends from the tool mountingportion and includes a drive shaft assembly that operably interfaceswith the rotary drive system. The drive shaft assembly is selectivelyaxially movable between a first position and a second position. Thesurgical tool further comprises a surgical end effector that isrotatably coupled to the elongate shaft assembly for selective rotationrelative thereto. A rotary transmission operably interfaces with thedrive shaft assembly and the surgical end effector such that when thedrive shaft assembly is in the first axial position, application of oneof the rotary drive motions to the drive shaft assembly by the rotarydrive system causes the rotary transmission to apply a first rotarycontrol motion to the surgical end effector and when the drive shaftassembly is in the second axial position, application of the rotarydrive motion to the drive shaft assembly by the rotary drive systemcauses the rotary transmission to apply a second rotary control motionto the surgical end effector.

In connection with yet another exemplary general form, there is provideda surgical instrument that comprises a handle assembly and a drive motorthat is operably supported by the handle assembly. An elongate shaftassembly operably extends from the handle assembly and includes a driveshaft assembly that operably interfaces with the drive motor and isselectively axially movable between a first position and a secondposition. A surgical end effector is rotatably coupled to the elongateshaft assembly for selective rotation relative thereto. A rotarytransmission operably interfaces with the drive shaft assembly and thesurgical end effector such that when the drive shaft assembly is in thefirst axial position, application of a rotary drive motion to the driveshaft assembly by the drive motor causes the rotary transmission toapply a first rotary control motion to the surgical end effector andwhen the drive shaft assembly is in the second axial position,application of the rotary drive motion to the drive shaft assembly bythe drive motor causes the rotary transmission to apply a second rotarycontrol motion to the surgical end effector.

Various exemplary embodiments also comprise a differential lockingsystem for a surgical instrument that includes a surgical end effectorthat is powered by a rotary drive shaft assembly that is movable betweena plurality of discrete axial positions. In at least one form, thedifferential locking system comprises at least one retention formationon the rotary drive shaft assembly that corresponds to each one of thediscrete axial positions. At least one lock member is operably supportedrelative to rotary drive shaft assembly for retaining engagement withthe at least one retention formation when the rotary drive shaftassembly is moved to the discrete axial positions associated therewith.

In connection with another exemplary general form, there is provided adifferential locking system for a surgical instrument that includes asurgical end effector powered by a rotary drive shaft assembly that ismovable between a first axial position and a second axial position. Inat least one exemplary form, the differential locking system comprises adifferential housing that operably interfaces with the rotary driveshaft assembly and the surgical end effector. At least one spring-biasedlock member operably supported by the differential housing for retainingengagement with a first portion of the rotary drive shaft assembly whenthe rotary drive shaft assembly is in the first axial position and theat least one spring-biased lock member further configured to retaininglyengage a second portion of the rotary drive shaft assembly when therotary drive shaft assembly is in the second axial position.

In connection with yet another exemplary general form, there is provideda differential locking system for a surgical instrument that includes asurgical end effector that is powered by a rotary drive shaft assemblythat is movable between a first axial position and a second axialposition. In at least one exemplary form, the differential lockingsystem comprises a differential housing that operably interfaces withthe rotary drive shaft assembly and the surgical end effector. At leastone spring member is provided on a portion of the rotary drive shaftassembly wherein each spring member defines a first retaining positionthat corresponds to the first axial position of the rotary drive shaftassembly and a second retaining position that corresponds to the secondaxial position of the rotary drive shaft assembly. A lock member isoperably supported by the differential housing and corresponds to eachof the at least one spring members for retaining engagement therewithsuch that the lock member retainingly engages the corresponding springmember in the first retaining position when the rotary drive shaftassembly is in the first axial position and the lock member retaininglyengages the corresponding spring member in the second retaining positionwhen the rotary drive shaft assembly is in the second axial position.

Various other exemplary embodiments comprise a surgical instrument thatincludes an end effector and a proximal rotary drive train assembly thatis operably coupled to a source of rotary and axial control motions. Theproximal rotary drive train assembly is longitudinally shiftable inresponse to applications of the axial control motions thereto. Thesurgical instrument further includes a distal rotary drive trainassembly that is operably coupled to the end effector to apply therotary control motions thereto. A proximal axial drive train assembly isoperably coupled to another source of axial control motions. A distalaxial drive train assembly is operably coupled to the end effector toapply the axial control motions thereto. The instrument furthercomprises a coupling arrangement for simultaneously attaching anddetaching the proximal rotary drive train assembly to the distal rotarydrive train assembly and the proximal axial drive train assembly to thedistal axial drive train assembly.

In connection with another general aspect, there is provided a couplingarrangement for attaching an end effector including a plurality ofdistal drive train assemblies that are configured to apply a pluralityof control motions to the end effector to corresponding proximal drivetrain assemblies communicating with a source of drive motions. In oneexemplary form, the coupling arrangement comprises a proximal attachmentformation on a distal end of each proximal drive train assembly and aproximal coupler member that is configured to operably support eachproximal drive train assembly therein such that the proximal attachmentformations thereon are retained in substantial coupling alignment. Adistal attachment formation is provided on a proximal end of each distaldrive train assembly. Each distal attachment formation is configured tooperably engage a proximal attachment formation on the distal end of acorresponding proximal drive train when brought into coupling engagementtherewith. A distal coupler member is operably coupled to the endeffector and is configured to operably support each distal drive traintherein to retain the distal attachment formations thereon insubstantial coupling alignment. A locking collar is movable from anunlocked position wherein the distal drive train assemblies may bedecoupled from the corresponding proximal drive train assemblies and alocked position wherein the distal drive train assemblies are retainedin coupled engagement with their corresponding proximal drive trainassemblies.

In connection with another general aspect, there is provided a surgicalinstrument that includes an end effector that is configured to performsurgical activities in response to drive motions applied thereto. Anexemplary form of the instrument further includes a source of drivemotions and a first proximal drive train assembly that operablyinterfaces with the source of drive motions for receiving correspondingfirst drive motions therefrom. A second proximal drive train assemblyoperably interfaces with the source of drive motions for receivingcorresponding second drive motions therefrom. A first distal drive trainassembly operably interfaces with the end effector and is configured toreceive the corresponding first drive motions from the first proximaldrive train assembly when it is operably coupled thereto. A seconddistal drive train assembly operably interfaces with the end effectorand is configured to receive the corresponding second drive motions fromthe second proximal drive train assembly when it is operably coupledthereto. The instrument further comprises a coupling arrangement thatincludes a first coupling member that operably supports the first andsecond proximal drive train assemblies therein. The coupling arrangementfurther includes a second coupling member that operably supports thefirst and second distal drive train assemblies therein and is configuredfor axial alignment with the first coupling member such that when thesecond coupling member is axially aligned with the first couplingmember, the first distal drive train assembly is in axial alignment withthe first proximal drive train assembly for operable engagementtherewith and the second distal drive train assembly is in axialalignment with the second proximal drive train assembly for operableengagement therewith. A locking collar is movably journaled on one ofthe first and second coupling members and is configured to move betweenan unlocked position wherein the first and second distal drive trainassemblies are detachable from the first and second proximal drive trainassemblies, respectively and a locked position wherein the first andsecond distal drive train assemblies are retained in operable engagementwith the first and second proximal drive train assemblies, respectively.

In accordance with another general aspect, there is provided a surgicalcartridge that includes a cartridge body that defines a paththerethrough for operably receiving a firing member of a surgicalinstrument. The surgical cartridge further includes an alignment memberthat is operably supported in the cartridge body and is configured tomove the firing member from an inoperable configuration wherein firingmember is misaligned with the path to an operable configuration whereinthe firing member is in alignment with the path when the firing memberis driven into contact therewith.

In accordance with yet another general aspect, there is provided an endeffector for a surgical instrument. In at least one form, the endeffector comprises a support member that has a slot and a lockout notchthat is adjacent to the slot. The end effector further comprises afiring member that is movable between an inoperable configuration and anoperable configuration, wherein the firing member is aligned with theslot and is structured to translate in the slot when it is in theoperable configuration and wherein the firing member is engaged with thelockout notch and misaligned with the slot when it is in the inoperableconfiguration.

Another exemplary embodiment comprises a surgical instrument thatincludes an elongate channel that is configured to removably support acartridge therein. In at least one form, the cartridge comprises acartridge body and an alignment member that is movably supported withinthe cartridge body for movement from a first position to a secondposition therein. The surgical instrument also comprises a firing memberthat is operably supported relative to the elongate channel for movementbetween a starting position and an ending position upon application ofactuation motions thereto. The firing member is incapable from movingfrom the starting position to the ending position unless the firingmember is in operable engagement with the alignment member in thecartridge body.

Another exemplary embodiment comprises an end effector for a surgicalinstrument. In at least one form, the end effector comprises an elongatechannel that is configured to removably support a cartridge therein. Afiring member is operably supported relative to the elongate channel formovement between a starting and ending position. An implement driveshaft is in operable engagement with the firing member for moving thefiring member between the starting and ending positions uponapplications of actuation motions thereto from a drive arrangement. Theimplement drive shaft is moveable from an inoperable position whereinthe implement drive shaft is out of operable engagement with the drivearrangement to an operable position wherein the implement drive shaft isin operable engagement with the drive arrangement. The end effectorfurther comprises an alignment member that is movably supported forcontact with the implement drive shaft to move the implement drive shaftfrom the inoperable position to the operable position upon installationof a cartridge in the elongate channel.

Another exemplary embodiment includes a surgical instrument thatcomprises an elongate channel and a cartridge that is removablysupported in the elongate channel. A firing member is operably supportedrelative to the elongate channel for movement between a starting andending position. An implement drive shaft is in operable engagement withthe firing member for moving the firing member between the starting andending positions upon applications of actuation motions thereto from adrive arrangement. The implement drive shaft is moveable from aninoperable position wherein the implement drive shaft is out of operableengagement with the drive arrangement to an operable position whereinthe implement drive shaft is in operable engagement with the drivearrangement. The surgical instrument further comprises an alignmentmember movably supported for contact with the implement drive shaft tomove the implement drive shaft from the inoperable position to theoperable position upon installation of a cartridge in the elongatechannel.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Although the present invention has been described herein in connectionwith certain disclosed exemplary embodiments, many modifications andvariations to those exemplary embodiments may be implemented. Forexample, different types of end effectors may be employed. Also, wherematerials are disclosed for certain components, other materials may beused. The foregoing description and following claims are intended tocover all such modification and variations.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A drive shaft assembly for a surgical instrument,the drive shaft assembly comprising: a plurality of movably interlockingjoint segments interconnected to form a flexible hollow tube, saidinterlocking joint segments being coupled together by a plurality ofloosely interlocking opposed T-shaped portions formed therein; and aflexible secondary constraining member in flexible constrainingengagement with the plurality of movably interlocking joint segments toretain the interlocking joint segments in movable interlockingengagement while facilitating flexing of the drive shaft assembly, saidflexible secondary constraining member comprising a helically woundmember extending around a perimeter of the hollow tube and wherein thehelically wound member includes a central portion and a proximal endportion and a distal end portion and wherein the proximal and distal endportions are wound tighter than the central portion.
 2. The drive shaftassembly of claim 1 wherein the helically wound member includes adesired pitch for transmitting rotary motion to the surgical instrument.3. The drive shaft assembly of claim 1 further comprising a surgical endeffector operably interfacing with the drive shaft assembly, thesurgical end effector configured to perform at least one action uponapplication of a control motion thereto.
 4. A composite drive shaftassembly for a surgical instrument, the drive shaft assembly comprising:a plurality of movably interlocking joint segments coupled together by aplurality of loosely interlocking opposed T-shaped portions cut into ahollow tube by a laser, the hollow tube having a proximal end and adistal end; and a flexible secondary constraining member in flexibleconstraining engagement with the plurality of movably interlocking jointsegments to retain the interlocking joint segments in movableinterlocking engagement while facilitating flexing of the drive shaftassembly, the flexible secondary constraining member comprising ahelically wound member extending around a perimeter of the hollow tubeand wherein the helically wound member includes a central portion and aproximal end portion and a distal end portion and wherein the proximaland distal end portions are wound tighter than the central portion. 5.The composite drive shaft assembly of claim 4 wherein the helicallywound member includes a desired pitch for transmitting rotary motion tothe surgical instrument.
 6. The composite drive shaft assembly of claim4 further comprising a surgical end effector operably interfacing withthe composite drive shaft assembly, the surgical end effector configuredto perform at least one action upon application of a control motionthereto.